Additive Manufacturing of Aluminum Using Friction Stir Deposition

Elfishawy, Ebtessam; Ahmed, Mohamed M. Z.; Seleman, Mohamed M. El-Sayed

doi:10.1007/978-3-030-36296-6_21

Cited by 23 publications

(16 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The AA2011 material plasticity during the FSD process is controlled by the amount of heat input introduced in the vortex zone through the AMPs material building from down to up. This phenomenon appears clearly in the AMP geometry based on the applied processing parameters [ 24 ].…”

Section: Resultsmentioning

confidence: 99%

“…This process may continue until all the rod length is consumed and became insufficient for more deposition. The shape of the consumed tool tends to form a conical shape, as shown in Figure 2 c. For AA2011-T6 group specimens, careful processing parameters were selected based on our experience in the field and the published data [ 24 , 29 ] to produce additive manufacturing parts. The required heat input to friction stir deposit such a hard material limits the process parameters to be 1200 rpm as a spindle rotation rate with 3, 6, and 9 mm/min feeding speeds.…”

Section: Methodsmentioning

confidence: 99%

“…In addition to the capability of the FSD technique to generate material builds of high-performance structures, it is considered an energy and cost-saving process [ 10 , 23 ]. Elfishawy et al [ 24 ] studied the possibility of multi-layers formation of die-cast Al–Si via FSD at the spindle rotation rate of 1200 rpm and different feeding speeds from 3 to 5 mm/min. The results showed sound structure with recrystallized refined grains.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

The Effect of Temper Condition and Feeding Speed on the Additive Manufacturing of AA2011 Parts Using Friction Stir Deposition

et al. 2021

Self Cite

View full text Add to dashboard Cite

In the current study, solid-state additive manufacturing (SSAM) of two temper conditions AA2011 was successfully conducted using the friction stir deposition (FSD) process. The AA2011-T6 and AA2011-O consumable bars of 20 mm diameter were used as a feeding material against AA5083 substrate. The effect of the rotation rate and feeding speed of the consumable bars on the macrostructure, microstructure, and hardness of the friction stir deposited (FSD) materials were examined. The AA2011-T6 bars were deposited at a constant rotation rate of 1200 rpm and different feeding speeds of 3, 6, and 9 mm/min, whereas the AA2011-O bars were deposited at a constant rotation rate of 200 mm/min and varied feeding speeds of 1, 2, and 3 mm/min. The obtained microstructure was investigated using an optical microscope and scanning electron microscope equipped with EDS analysis to evaluate microstructural features. Hardness was also assessed as average values and maps. The results showed that this new technique succeeded in producing sound additive manufactured parts at all the applied processing parameters. The microstructures of the additive manufactured parts showed equiaxed refined grains compared to the coarse grain of the starting materials. The detected intermetallics in AA2011 alloy are mainly Al2Cu and Al7Cu2Fe. The improvement in hardness of AA2011-O AMPs reached 163% of the starting material hardness at the applied feeding speed of 1 mm/min. The hardness mapping analysis reveals a homogeneous hardness profile along the building direction. Finally, it can be said that the temper conditions of the starting AA2011 materials govern the selection of the processing parameters in terms of rotation rate and feeding speed and affects the properties of the produced additive manufactured parts in terms of hardness and microstructural features.

show abstract

Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

The Effect of Temper Condition and Feeding Speed on the Additive Manufacturing of AA2011 Parts Using Friction Stir Deposition

et al. 2021

Self Cite

View full text Add to dashboard Cite

show abstract

“…The stirring action of the consumable rod eliminated casting porosities or shrinkage cavities (Figure 9a) by closing them. The AFS-D parameters [20,34,44], had a pronounced effect on the microstructure of the built materials due to the intensified stirring effect during the deposition process. Feeding speed as a processing parameter showed a significant influence on the grain size microstructure of the deposited materials at a constant rotation speed of 1200 rpm, as shown in Figure 10a-f.…”

Section: Microstructure Of the Consumable Rod And A356 Ampsmentioning

confidence: 99%

“…Due to the frictional heat, the feed material is softened and plastically deformed, which bonds to the substrate. Continuous bonding of more plastically deformed feed material to the substrate plate makes the deposition of the first layer, and subsequently, the addition of layers one by one makes a 3D object of a desired thickness [20][21][22]. Dilip et al [23] studied the microstructure features of fabricated AA2014-T6 by AFSD at 800 rpm, 1 mm/min, at an axial pressure of 35 MPa.…”

Section: Introductionmentioning

confidence: 99%

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

et al. 2021

Self Cite

View full text Add to dashboard Cite

In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect of feeding speeds of 3, 4, and 5 mm/min at a constant rotational speed of 1200 rpm on the macrostructure, microstructure, and hardness of the additive manufacturing parts (AMPs) was investigated. Various techniques (OM, SEM, and XRD) were used to evaluate grain microstructure, presence phases, and intermetallics for the as-cast material and the AMPs. The results showed that the friction stir deposition technique successfully produced sound additive manufactured parts at all the applied feeding speeds. The friction stir deposition process significantly improved the microstructure of the as-cast alloy by eliminating porosity and refining the dendritic α-Al grains, eutectic Si phase, and the primary Si plates in addition to intermetallic fragmentation. The mean values of the grain size of the produced AMPs at the feeding speeds of 3, 4, and 5 mm/min were 0.62 ± 0.1, 1.54 ± 0.2, and 2.40 ± 0.15 µm, respectively, compared to the grain size value of 30.85 ± 2 for the as-cast alloy. The AMPs exhibited higher hardness values than the as-cast A356 alloy. The as-cast A356 alloy showed highly scattered hardness values between 55 and 75.8 VHN. The AMP fabricated at a 3 mm/min feeding speed exhibited the maximum hardness values between 88 and 98.1 VHN.

show abstract

Solid State Additive Manufacturing: An Unconventional Technique to Fabricate Composite

Maurya,

Kumar

2024

Materials Horizons: From Nature to Nanomaterials

View full text Add to dashboard Cite

Additive Manufacturing of Aluminum Using Friction Stir Deposition

Cited by 23 publications

References 23 publications

The Effect of Temper Condition and Feeding Speed on the Additive Manufacturing of AA2011 Parts Using Friction Stir Deposition

The Effect of Temper Condition and Feeding Speed on the Additive Manufacturing of AA2011 Parts Using Friction Stir Deposition

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

Solid State Additive Manufacturing: An Unconventional Technique to Fabricate Composite

Contact Info

Product

Resources

About