Additive friction stir deposition(AFSD) is attractive for its ability to create freeform and fully-dense structures without melting and solidi cation. Hence, additive friction stir deposition is an alternative to fusion-based additive manufacturing technology. In this study, the in uence of AFSD parameter (i.e. rotational speed and feed rate) on the mechanical properties and microstructure of 6061 aluminum alloy is investigated. The as-deposited 6061 aluminum alloy exhibits relatively homogeneous microstructure with extensive equiaxed grains. Compared to the base material, the ultimate tensile strength is ranged from 320 MPa to 210MPa, decreasing to 65% of the feedstock material. The grain boundary misorientation distribution indicates that continuous dynamic recrystallization occurs during the AFSD process. Furthermore, it is evidence that the grain size and ultimate tensile strength are positive correlated with feed rate and rotational speed, whereas the elongation at break decreases with the increase in feed rate and rotational speed.

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