Microstructure-deformation relationship of additive friction stir-deposition Al–Mg–Si

Phillips, B.J.; Avery, D. Z.; Liu, T.; Rodriguez, Omar; Mason, C. J. T.; Jordon, J.B.; Brewer, Luke N.; Allison, P. G.

doi:10.1016/j.mtla.2019.100387

Cited by 144 publications

(64 citation statements)

References 37 publications

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“…For AA 7075, the grain refinement is expected to proceed via dynamic recovery, which leads to sub-grain formation, followed by strain-induced grain rotation, resulting in high angle grain boundaries [28,29]. This process is generally referred to as continuous dynamic recrystallization, which has been observed in the additive friction stir deposition of other Al alloys [30,31].…”

Section: Double Through-hole Fillingmentioning

confidence: 99%

Additive Friction Stir-Enabled Solid-State Additive Manufacturing for the Repair of 7075 Aluminum Alloy

et al. 2019

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The repair of high strength, high performance 7075 aluminum alloy is essential for a broad range of aerospace and defense applications. However, it is challenging to implement it using traditional fusion welding-based approaches, owing to hot cracking and void formation during solidification. Here, the use of an emerging solid-state additive manufacturing technology, additive friction stir deposition, is explored for the repair of volume damages such as through -holes and grooves in 7075 aluminum alloy. Three repair experiments have been conducted: double through-hole filling, single through-hole filling, and long, wide-groove filling. In all experiments, additive friction stir deposition proves to be effective at filling the entire volume. Additionally, sufficient mixing between the deposited material and the side wall of the feature is always observed in the upper portions of the repair. Poor mixing and inadequate repair quality have been observed in deeper portions of the filling in some scenarios. Based on these observations, the advantages and disadvantages of using additive friction stir deposition for repairing volume damages are discussed. High quality and highly flexible repairs are expected with systematic optimization work on process control and repair strategy development in the future.

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Section: Double Through-hole Fillingmentioning

confidence: 99%

Additive Friction Stir-Enabled Solid-State Additive Manufacturing for the Repair of 7075 Aluminum Alloy

et al. 2019

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“…When lower temperatures are involved in the AM process, dissimilar material structures can be fabricated without generating harmful intermetallic compounds [ 53 ]. Additive Friction Stir-Deposition (AFS-D) is a solid-state AM process derived from friction stir welding, preventing hot cracking by avoiding liquid–solid phase transformations [ 54 ]. Friction surfacing for layer-by-layer manufacture of three-dimensional metallic parts can be realized in both single- and multi-track approaches, with excellent bonding between individual layers and tracks [ 55 ].…”

Section: Additive Manufacturingmentioning

confidence: 99%

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

et al. 2021

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High requirements imposed by the competitive industrial environment determine the development directions of applied manufacturing methods. 3D printing technology, also known as additive manufacturing (AM), currently being one of the most dynamically developing production methods, is increasingly used in many different areas of industry. Nowadays, apart from the possibility of making prototypes of future products, AM is also used to produce fully functional machine parts, which is known as Rapid Manufacturing and also Rapid Tooling. Rapid Manufacturing refers to the ability of the software automation to rapidly accelerate the manufacturing process, while Rapid Tooling means that a tool is involved in order to accelerate the process. Abrasive processes are widely used in many industries, especially for machining hard and brittle materials such as advanced ceramics. This paper presents a review on advances and trends in contemporary abrasive machining related to the application of innovative 3D printed abrasive tools. Examples of abrasive tools made with the use of currently leading AM methods and their impact on the obtained machining results were indicated. The analyzed research works indicate the great potential and usefulness of the new constructions of the abrasive tools made by incremental technologies. Furthermore, the potential and limitations of currently used 3D printed abrasive tools, as well as the directions of their further development are indicated.

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“…For example, feedstock made from aluminum alloys (e.g. 2xxx [36,55], 6xxx [31], and 7xxx [49,56]) with a coarse microstructure (grain size ∼ 100-200 μm) may have their grain size reduced to 1-5 μm after AFSD. Figure 2(b) shows an example for AFSD of AA2024, with a comparison of the microstructure before and after printing.…”

Section: Microstructurementioning

confidence: 99%

“…Inspired by solid-state welding, several deformation-based metal additive manufacturing approaches have emerged during the last few years [25]. These include ultrasonic additive manufacturing [26,27], cold spray additive manufacturing [28,29], and additive friction stir deposition (AFSD) [30,31]. Without material melting, these approaches exploit deformation bonding to implement layer adhesion via ultrasonic vibration, particle impact, and friction stirring, respectively.…”

Section: Introductionmentioning

confidence: 99%

Additive friction stir deposition: a deformation processing route to metal additive manufacturing

Mishra

2020

Materials Research Letters

131

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As the forging counterpart of fusion-based additive processes, additive friction stir deposition offers a solid-state deformation processing route to metal additive manufacturing, in which every voxel of the feed material undergoes severe plastic deformation at elevated temperatures. In this perspective article, we outline its key advantages, e.g. rendering fully-dense material in the as-printed state with fine, equiaxed microstructures, identify its niche engineering uses, and point out future research needs in process physics and materials innovation. We argue that additive friction stir deposition will evolve into a major additive manufacturing solution for industries that require high load-bearing capacity with minimal post-processing. IMPACT STATEMENT This paper delineates additive friction stir deposition, which offers a solid-state deformation processing route to metal additive manufacturing and renders fully-dense material with fine, equiaxed microstructures in the as-printed state.

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Microstructure-deformation relationship of additive friction stir-deposition Al–Mg–Si

Cited by 144 publications

References 37 publications

Additive Friction Stir-Enabled Solid-State Additive Manufacturing for the Repair of 7075 Aluminum Alloy

Additive Friction Stir-Enabled Solid-State Additive Manufacturing for the Repair of 7075 Aluminum Alloy

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

Additive friction stir deposition: a deformation processing route to metal additive manufacturing

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