Sc/Zr microalloying on strength-corrosion performance synergy of wire-arc directed energy deposited Al-Mg

WADED Al-Mg and Al-Mg-Sc-Zr aluminium alloy thin-wall components were produced. Heat treatment (350°C aging for 4 h) was further conducted. The effects of Sc/Zr addition on porosity, microstructure, mechanical properties and corrosion behaviour were investigated. With Sc/Zr adding, pore area fraction decreased from 0.208 to 0.005% and grain size decreased from 84.34 to 19.54 μm. In WADED Al-Mg-Sc-Zr component, microstructure showed refined equiaxed grains. Mechanical properties were improved with 360 MPa ultimate tensile strength (UTS), 185 MPa yield strength, and 23.31% elongation. After heat treatment, UTS increased to 388 MPa with good ductility (22.53%) maintained. The grain refinement and Al₃(Sc, Zr) particles were the key factors for mechanical property improvement. The corrosion behaviour was improved with introduced Sc/Zr and further optimised after heat treatment. The corrosion exhibited layered characteristics due to the distribution of primary Al₃(Sc, Zr) while minor-size secondary Al₃(Sc, Zr) along grain boundaries improved the corrosion behaviour.