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A gradient transition zone was obtained using electron beam deposition from AA4047 wire on AA7075 substrate and characterized for microstructures, tensile strength and corrosion resistance. The microstructure of the transition zone was composed of aluminum alloy grains, Al/Si eutectics and Fe-rich and Si-rich particles. Such a microstructure provided strength comparable to that of AA7075-T42 substrate but more intense corrosion due to the higher amount of anodic Mg 2 Si particles. The as-deposited AA4047 zone formed above the transition zone was composed of aluminum alloy dendrites and interdendritic Al/Si eutectics with low mechanical strength and high corrosion potential.

Microstructure and Corrosion Resistance of AA4047/AA7075 Transition Zone Formed Using Electron Beam Wire-Feed Additive Manufacturing