Effect of inter-pass temperature on the fatigue properties of wire-arc additively manufactured aluminium 5183

Author: Johann Jordaan

  • Thesis download: available for open access on 8 Feb 2026.

Jordaan, Johann, 2023 Effect of inter-pass temperature on the fatigue properties of wire-arc additively manufactured aluminium 5183, Flinders University, College of Science and Engineering

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Wire-arc additive manufacturing is an upcoming technology that allows for free-form, near

net shape manufacturing of large components using a welding process. This process is

rapidly becoming a more efficient way to produce complex components using available

welding wire. Due to its common use in critical industries that require large and complex

parts, aluminium is a promising material for use in the additive manufacturing industry.

The critical nature of these components, however, require extensive knowledge of material

properties such as tensile strengths and fatigue behaviour – which is currently very limited.

Optimisation of parameters such as inter-pass temperature has been proposed to improve

deposited material quality, but the relationship between inter-pass temperature and

mehcnaicl and fatigue properties is not well understood. Furthermore, due to the significant

effect of build direction on WAAM materials, specimen orientation was also considered.

Using AML3D’s proprietary WAM manufacturing technique, test pieces were produced using

aluminium alloy 5183 at inter-pass temperatures of 100oC and 150oC. Tensile, hardness

and fatigue testing were then completed, along with microstructural assessments, fatigue

fractography and elemental analysis.

Inter-pass temperature was shown to have no significant effect on tensile or hardness

properties, with reported yield and ultimate tensile strengths of 129.5 and 272.8 MPa

respectively. The increased inter-pass temperature did however have a noticeable effect on

fatigue life, with low-medium cycle fatigue life showing an increase of approximately 20%.

Build direction was shown to have no significant effect on tensile properties but showed a

noticeable effect on both hardness and fatigue life. Metallographic examination and fatigue

fractography highlighted large amounts of internal porosity, with most fatigue fractures

initiating at sites of porosity.

The increased inter-pass temperature resulted in an approximate 43% increase in

production efficiency, highlighting the potential benefits of optimising the inter-pass

temperature. The presence of internal defects, however, need to be closely monitored as

these initiate the majority of failures. Further work investigating the effect of inter-pass

temperature and welding process on porosity is suggested, while continuing to optimise

production efficiency of the WAAM process.

Keywords: aluminium, aluminium alloy, 5183, additive manufacturing, wire-arc additive manufacturing, WAAM, fatigue, fatigue testing, material properties, material testing

Subject: Engineering thesis

Thesis type: Masters
Completed: 2023
School: College of Science and Engineering
Supervisor: Dr. Reza Hashemi