This project explores the mechanical performance of AER 5356 aluminum alloy for use in aircraft wing stiffeners, utilizing Cold Metal Transfer (CMT)-based Wire Arc Additive Manufacturing (WAAM). The study includes extensive parameter optimization, simulation, and post-processing analysis to validate the material for aerospace-grade structural applications.
- Fabricate aluminum test walls using WAAM with varying welding parameters.
- Analyze the mechanical properties of AER 5356 before and after cryogenic treatment.
- Evaluate performance using industry-standard tests (Micro Tensile, EBSD, Hardness, XRD).
- Investigate porosity levels and microstructure behavior under cryogenic conditions.
- CMT-WAAM (Cold Metal Transfer – Wire Arc Additive Manufacturing)
- SolidWorks – 3D CAD modeling
- ANSYS – Finite Element Analysis (Static)
- Cryogenic Treatment
- Material Testing – XRD, EBSD, Hardness Test, Micro Tensile Test
- 🔧 30+ welding trials conducted for parameter optimization
- 💪 UTS increased by 37% (up to 359.92 MPa) after cryogenic treatment
- 🔬 Yield strength improved by 67% (up to 256.52 MPa)
- 📈 Elongation reached 46.25%, indicating excellent ductility
- 🧪 Significant reduction in porosity, improving weld density and uniformity
- Current: ~190 A
- Voltage: 17.2 V
- Wire Speed: 11.5 m/min
- Travel Speed: 80–110 cm/min
- Additive Manufacturing (WAAM)
- Materials Testing & Characterization
- CAD Design & Simulation
- Research Methodology & Data Analysis
- Process Optimization
- Ananthakrishnan R.P
- Aromal J
- Mohammed Lafir
- Athithya Prabhu
SRM Institute of Science and Technology, Ramapuram Campus
Department of Mechanical Engineering – 6th Semester Minor Project
Academic Year 2024–25
For detailed methodology, experimental data, and results, refer to the full Project Report.
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