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

Abstract

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.

Microstructural characterization and mechanical properties of AlMg alloy fabricated by additive friction stir deposition

“…However, the hardness of AMPs fabricated using O temper alloy was higher than that in the starting material and increased by approximately 163% over the hardness of the initial material [38]. AFSD was also applied to fabricate aluminum matrix composites, where ne equiaxed grains were observed, and the deposited material was completely dense with the substrate, no pores can be observed [39][40][41].…”

Traverse and longitudinal analysis of AA5083/AA6082 dissimilar joint

“…Currently, FSW allows for the incorporation of various materials in the production of weldments, enabling the creation of both similar and dissimilar joints within single structures. Extensive research has been conducted to investigate the effects of FSW on different materials and their properties, focusing on extracting samples from diverse orientations such as traverse, longitudinal, and diagonal [10][11][12][13][14][15][16][17]. Furthermore, samples have been collected from different locations along the joint line, including the start, middle, and end sections, to comprehensively examine their properties [18][19][20][21][22].…”

“…A study was conducted to investigate the microstructural and mechanical characteristics of additive friction stir-deposition on a 63.5 mm thick plate made of aluminium alloy 5083 [14]. The focus of this investigation was to analyze the effects of lubrication on material anisotropy.…”

“…Researchers have also paid significant attention to sample location, particularly when investigating dissimilar joints, as the contrasting materials offer valuable insights. The selection of sample locations has been emphasized by numerous researchers as a focal point of their studies [10][11][12][13][14][15][16][17][18][19][20][21][22].…”

Ballistic Evaluation of Aluminum Alloy (AA) 7075 Plate Repaired by Additive Friction Stir Deposition Using AA7075 Feedstock

“…AFSD is capable of generating high quality repairs free from voids and cracks along with low residual stresses, and high adhesion to the base material, making it a supremely attractive method for the repair of critical components such as vehicle or personnel protection systems [8]. Considerable research exists on the additive manufacturing capabilities of AFSD on a variety of aluminum alloys including A356 [9], AA5083 [10], AA6061 [11][12][13][14][15], AA7050 [16,17], and AA7075 [18,19]; but relatively little work exists on the repair capabilities [20][21][22][23][24]. There is also a fundamental lack of work elucidating the effectiveness of repaired AA7075 against subsequent ballistic impacts.…”