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

Additive Manufacturing of Aluminium Foams via H2-infused shielding gas – technological potential and process evaluation | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Additive Manufacturing of Aluminium Foams via H 2 -infused shielding gas – technological potential and process evaluation Marcel Köhler, Hannes Blaschke, Sven Jüttner This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8191268/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract 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. Full Text Additional Declarations No competing interests reported. Supplementary Files AlSi10MgshortarcN2H2shieldinggas.mp4 Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8191268","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":558138538,"identity":"f4475134-98a7-4957-acba-545038fc2488","order_by":0,"name":"Marcel 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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\u003csub\u003e2\u003c/sub\u003e-infused shielding gas.\u003c/p\u003e","manuscriptTitle":"Additive Manufacturing of Aluminium Foams via H2-infused shielding gas – technological potential and process evaluation","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-12-11 10:54:44","doi":"10.21203/rs.3.rs-8191268/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"5621f55e-4ed0-41e4-a8e2-b88c81106eda","owner":[],"postedDate":"December 11th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2026-03-23T02:23:12+00:00","versionOfRecord":[],"versionCreatedAt":"2025-12-11 10:54:44","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8191268","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8191268","identity":"rs-8191268","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}