Hardness Distribution of Al2050 Parts Fabricated Using Additive Friction Stir Deposition

Abstract

The solid-state additive friction stir deposition (AFSD) process is a layer-by-layer metal 3D-printing technology. In this study, AFSD is used to fabricate Al–Cu–Li 2050 alloy parts. The hardness values for various regions of the as-deposited built parts are measured, and the results are contrasted with those of the feedstock material. The as-fabricated Al2050 parts are found to have a unique hardness distribution due to the location-specific variations in the processing temperature profile. The XRD results indicate the presence of the secondary phases in the deposited parts, and EDS mapping confirms the formation of detectable alloying particles in the as-deposited Al2050 matrix. The AFSD thermal–mechanical process causes the unique hardness distribution and the reduced microhardness level in the AFSD components, in contrast to those of the feedstock material.

The Effects of Layer Thickness on the Mechanical Properties of Additive Friction Stir Deposition-Fabricated Aluminum Alloy 6061 Parts

“…This configuration results in a greater susceptibility to crack growth and accelerated fracture due to the presence of layer boundary defects or weakened interfacial layers [77]. For AFSD, the layer boundaries are formed differently from a regular layer-by-layer printing because of re-stringing of the previous layer [29,31]. Saber et al investigated the layer-by-layer architecture of distinct segments within as-built AA6061 parts created via the AFSD process, employing neutron imaging techniques as a non-destructive evaluation methodology [30].…”

“…In the AFSD manufacturing process, the mixture of a high temperature and strain rate leads to dynamic recrystallization of the material being deposited [1,29,66]. Consequently, the as-deposited material exhibits smaller equiaxed grain sizes compared to the feedstock material [29,31]. Zeng et al reported a grain size of 8.5 ± 3 µm for the as-deposited AA6061 parts and 163.5 ± 96 µm for the feedstock material [29].…”

“…Aluminum alloys, known for their lightweight nature, possess exceptional strength-to-weight ratios, as well as remarkable resistance to corrosion [28]. Notably, the literature has documented the successful utilization of AFSD in the manufacturing of AA6061 [19,29,30], AA2050 [31], AA2011 [32], AA2024 [13], AA2219 [33,34], AA5083 [35,36], AA5B70 [37], and AA7075 [24,[38][39][40][41] parts, showcasing the versatility and potential of this technique for aluminum alloy processing. The deposition of parts made of other metal alloys is also reported in the literature.…”

A comparative study of machine learning in predicting the mechanical properties of the deposited AA6061 alloys via additive friction stir deposition

“…Additionally, Ghadimi et al. confirmed that the top layer of the deposited Al2050 part exhibited higher microhardness (about 118 HV) than the middle layer (about 80 HV), attributing to the re‐stirring and re‐heating of the AFSD process [8] . Therefore, it is essential to understand the effect of the thermal evolution and deformation conditions on the performance and to predict the mechanical properties with in‐process feedback control of the process parameters.…”

Mechanical Performance and Microstructural Characterization of Light Alloys

“…More recently, additive manufacturing and dissimilar metal welding have attracted much attention for its various advantages, such as high efficiency and easy repeatability. Nonetheless, due to the manufacturing characteristics [5][6][7], mechanical anisotropy and performance distribution may become inhomogeneous and further deep microstructural characterizations should be performed.…”