At MX3D, we’re continuously exploring new materials to unlock greater possibilities for robotic 3D metal printing with Wire Arc Additive Manufacturing (WAAM). In collaboration with Novametal, a supplier of premium welding materials, we recently carried out a comprehensive series of material qualification tests. The goal is to determine whether selected Novametal alloys meet the mechanical and quality standards required for WAAM applications, and to expand our library of materials for our customers with the M1/MX Metal AM Systems.
This publication outlines the results of this testing campaign, covering tensile strength, impact resistance, and bend performance for two high-performance alloys: Aluminum ER5183 and Nickel Alloy NiCrMo-3.
Materials Overview: Why These Alloys?
WAAM opens up possibilities for producing large, complex metal parts with a shorter lead time than conventional methods. However, not every material behaves the same under arc-based additive manufacturing , and ensuring weldability, mechanical integrity, and repeatability is essential.
With Novametal, we selected two wires to test their performance with WAAM:
- Aluminum ER5183, a high-strength aluminum alloy commonly used in shipbuilding, offshore structures, and cryogenic applications, and
- Nickel Alloy NiCrMo-3 (ERNiCrMo-3), a corrosion-resistant, high-performance nickel-based alloy designed for aggressive environments such as chemical processing, marine, and energy sectors.
It’s key that welding wires for WAAM deliver stable arc characteristics, consistent feed, and high mechanical performance in the as-printed condition. These tests aim to validate whether the selected Novametal alloys meet those demanding criteria.
Testing Methods: ASME Driven Assurance
The material tests were conducted following ASME Section IX, Article VI guidelines, ensuring a rigorous and industry-approved methodology.
For each material, we produced both thin (5mm) and thick (50mm) WAAM-printed test pieces using MX3D’s robotic WAAM systems. These samples were then subjected to:
- Tensile Tests — to measure Ultimate Tensile Strength (UTS), Yield Tensile Strength (YTS), and elongation (A%).
- Impact Tests — performed at relevant temperatures to assess toughness.
- Bend Tests — evaluating ductility and weld soundness.
All Non-Destructive Testing (NDT) reports, X-rays, and mechanical testing data were documented throughout the process.
Test Results Per Alloy
The test results for the aluminum ER5183 wire were as follows:
Aluminum ER5183
Thin (5mm) Samples
- UTS: 282 MPa
- Bend Test: Acceptable
Thick (50mm) Samples
UTS: 286 MPa
- YTS: 128 MPa
- Elongation (A%): 30%
- Impact Test @20°C: 30 J
- Bend Test: Acceptable
Summary: The ER5183 alloy demonstrated good weldability and mechanical performance in both thicknesses, with consistent UTS values and acceptable ductility for structural WAAM applications.
The test results for the nickel alloy NiCrMo-3 were as follows:
Nickel Alloy NiCrMo-3
Thin (5mm) Samples
- UTS: 616 MPa
- Bend Test: Acceptable
Thick (50mm) Samples
- UTS: 683 MPa
- YTS: 401 MPa
- Elongation (A%): 58%
- Impact Test @-196°C: 219 J
- Bend Test: Acceptable
Summary: NiCrMo-3 exhibits excellent strength, ductility, and remarkable toughness at cryogenic temperatures. Its performance confirms its suitability for demanding energy, offshore, and marine applications via WAAM.
Conclusion: New Materials, New Possibilities
The successful qualification of Aluminum ER5183 and Nickel Alloy NiCrMo-3 marks a significant addition to the range of alloys compatible with MX3D’s M1 and MX Metal AM Systems . Both materials demonstrated consistent weldability and mechanical integrity, meeting the stringent demands of ASME Section IX testing.
What does this mean for you?
If your projects require corrosion-resistant nickel alloys or high-strength aluminum components, MX3D can now print them. Whether you’re looking to manufacture in-house with your own M1/MX Metal System or order custom parts from our Amsterdam production facility, these new qualified materials are available for your next application.
Contact us today to discuss the quality of printing your metal parts with WAAM and discover how MX3D can help you manufacture smarter, faster, and more flexible
