Deformation-based additive manufacturing of 7075 aluminum with wrought-like mechanical properties

Yoder, Jake K.; Griffiths, R. Joey; Yu, Hang

doi:10.1016/j.matdes.2020.109288

Cited by 84 publications

(11 citation statements)

References 10 publications

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“…In three of those investigations [9,10,19], this loss was attributed to the coarsening and non-uniform dispersion of the precipitates in the deposited state; those precipitates represent the dominant strengthening mechanism in the corresponding Al alloys [21]. Application of post-deposition heat treatments-solutionizing and ageing-has been reported to result in near-full recovery of optimal mechanical properties [22] because the dominant strengthening mechanism has been restored. Finally, in the Mg-based WE43 alloy, grain refinement is also observed.…”

Section: Introductionmentioning

confidence: 99%

Microstructure Development in Additive Friction Stir-Deposited Cu

Priedeman

Phillips

Lopez

et al. 2020

Metals

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This work details the additive friction stir-deposition (AFS-D) of copper and evaluation of its microstructure evolution and hardness. During deposition, a surface oxide is formed on the deposit exterior. A very fine porosity is formed at the substrate–deposit interface. The deposit (four layers of 1 mm nominal height) is otherwise fully dense. The grains appear to have recrystallized throughout the deposit with varying levels of refinement. The prevalence of twinning was found to be dependent upon the grain size, with larger local grain sizes having a higher number of twins. Vickers hardness measurements reveal that the deposit is softer than the starting feedstock. This result indicates that grain refinement and/or higher twin densities do not replace work hardening contributions to strengthen Cu processed by additive friction stir-deposition.

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Section: Introductionmentioning

confidence: 99%

Microstructure Development in Additive Friction Stir-Deposited Cu

Priedeman

Phillips

Lopez

et al. 2020

Metals

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“…The softened feed material is fed through the tool and metallurgically bonds with the substrate through high shear and severe plastic deformation at the interface [3] . AFSD has been demonstrated to produce site-specific buildup of fully-dense material in as-printed conditions with fine, equiaxed microstructures [4] , [5] , [6] , [7] , [8] .…”

Section: Experimental Design Materials and Methodsmentioning

confidence: 99%

Optical image and Vickers hardness dataset for repair of 1080 steel using additive friction stir deposition of Aermet 100

Chou

Eff

Cox³

et al. 2022

Data in Brief

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This article presents optical images, measurements of heat affected zone depths, and peak Vickers hardness values from the heat affected zone regions of a 1080 steel plate substrate with a machined groove “flaw” repaired using additive friction stir deposition of Aermet 100. The deposition of Aermet 100 was performed using a L3 Meld machine with 9.525 mm (0.375 inch) square bar profile Aermet 100 feedstock rods fed through a hollow, 10.16 mm (0.4 inch) diameter, rotating tool onto a 1.02 mm thick 1080 steel plate with a machined groove “flaw” along the plate's length and bisecting the plate's width. The depth of the machined groove “flaw” ranged from 4.7625, 6.35, and 9.525 mm. The data is categorized into four groups: multi-layer builds deposited at room temperature with and without a cooling plate, 2-layer builds deposited at room temperature without a cooling plate, single-layer builds deposited at room temperature without a cooling plate, and a design of experiments for single-layer builds that varied the spindle rotation speed (RPM), travel speed (mm/min), material feed rate (mm/min), and pre-heat temperature (°C) of the deposition. The data shows the parameter conditions that achieved flaw-free consolidated repairs and the associated depth and peak Vickers hardness of the heat affected zone. Optical images of cross-sectioned deposition regions were obtained using an optical microscope with Leco Olympus DP27 macro camera, and Vickers hardness line traces were measured along the depth of the deposited and heat affected zone extending into the substrate on cross-sectioned samples using a Leco LM 247AT microhardness tester. The depth of the heat affected zone is reported as the measured average of five individual data points. Peak values for Vickers hardness for the heat affected zone decreased for pre-heated conditions at 329°C compared to builds conducted at room temperature of 21°C. This dataset provides visual characterization and associated hardness measurements of as-deposited repairs of dissimilar steel alloys. This article can be used to inform parameter selection for additive friction stir deposition of dissimilar steel materials for repair and solid-state additive manufacturing applications.

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“…Following AFS-D, these grains are refined into 3.16 µm diameter equiaxed grains with a standard deviation of 1.38 µm. As denoted by recent studies of Al-Cu [18], Al-Mg-Si [27,28,47], and Al-Zn Mg-Cu [29,48], AFS-D refines aluminum alloy grain structures via geometric, continuous dynamic recrystallization. Mason et al [33] established that grain sizes were generally larger in the first layers of the deposit due to the increased thermal exposure as additional layers are built.…”

Section: Parameter Studymentioning

confidence: 99%

Microstructural and Mechanical Characterization of Additive Friction Stir-Deposition of Aluminum Alloy 5083 Effect of Lubrication on Material Anisotropy

et al. 2021

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Additive Friction Stir-Deposition (AFS-D) is a transformative, metallic additive manufacturing (AM) process capable of producing near-net shape components with a wide variety of material systems. The solid-state nature of the process permits many of these materials to be successfully deposited without the deleterious phase and thermally activated defects commonly observed in other metallic AM technologies. This work is the first to investigate the as-deposited microstructure and mechanical performance of a free-standing AA5083 deposition. An initial process parameterization was conducted to down-select optimal parameters for a large deposition to examine build direction properties. Microscopy revealed that constitutive particles were dispersed evenly throughout the matrix when compared to the rolled feedstock. Electron backscatter diffraction revealed a significant grain refinement from the inherent dynamic recrystallization from the AFS-D process. Tensile experiments determined a drop in yield strength, but an improvement in tensile strength in the longitudinal direction. However, a substantial reduction in tensile strength was observed in the build direction of the structure. Subsequent fractographic analysis revealed that the recommended lubrication applied to the feedstock rods, necessary for successful depositions via AFS-D, was ineffectively dispersed into the structure. As a result, lubrication contamination became entrapped at layer boundaries, preventing adequate bonding between layers.

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Deformation-based additive manufacturing of 7075 aluminum with wrought-like mechanical properties

Cited by 84 publications

References 10 publications

Microstructure Development in Additive Friction Stir-Deposited Cu

Microstructure Development in Additive Friction Stir-Deposited Cu

Optical image and Vickers hardness dataset for repair of 1080 steel using additive friction stir deposition of Aermet 100

Microstructural and Mechanical Characterization of Additive Friction Stir-Deposition of Aluminum Alloy 5083 Effect of Lubrication on Material Anisotropy

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