Additive Manufacturing of Aluminium Foams via H2-infused shielding gas – technological potential and process evaluation

Composite materials made from aluminum foam are increasingly utilized in aerospace and automotive industries due to their low density, high energy absorption capacity, and resistance to corrosion. Additive manufacturing processes offer several advantages over conventional manufacturing techniques, including the capability to fabricate significantly more geometrically complex components without the need for costly tooling. Direct Energy Deposition processes, such as DED-Arc (also known as Wire Arc Additive Manufacturing (WAAM)), facilitate the additive production of near-net-shape components at high build rates. This paper proposes a cost effective and easy to implement manufacturing approach using standard filler wires and equipment as well as H ₂ -infused shielding gas.