Repair of aluminum 6061 plate by additive friction stir deposition

Martin, L.; Luccitti, Allen; Walluk, Mark R.

doi:10.1007/s00170-021-07953-z

Cited by 30 publications

(8 citation statements)

References 32 publications

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“…Metallographic examinations revealed a well-bonded interface between the repair filler and the base material. L.P. Martin et al [17] repaired an aluminum 6061 plate using additive friction stir deposition.…”

Section: Introductionmentioning

confidence: 99%

Enhancing Additive Restoration of Damaged Polymer Curved Surfaces through Compensated Support Beam Utilization

Zhang,

Guo

2024

Processes

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As additive manufacturing advances, it offers a cost-effective avenue for structurally repairing components. However, a challenge arises in the additive repair of suspended damaged surfaces, primarily due to gravitational forces. This can result in excessive deformation during the repair process, rendering the formation of proper repair impractical and leading to potential failure. In light of this rationale, conventional repair techniques are impractical for extensively damaged surfaces. Thus, this article proposes a novel repair methodology that is tailored to address large-area damage. Moreover, and departing from conventional practices involving the addition and subsequent subtraction of materials for precision machining, the proposed process endeavors to achieve more precise repair outcomes in a single operation. This paper introduces an innovative repair approach employing fused deposition modeling (FDM) to address the complexities associated with the repair of damaged polymer material parts. To mitigate geometric errors in the repaired structural components, beams with minimal deformation are printed using a compensation method. These beams then serve as supports for overlay printing. The paper outlines a methodology by which to determine the distribution of these supporting beams based on the shape of the damaged surface. A beam deformation model is established, and the printing trajectory of the compensated beam is calculated according to this model. Using the deformation model, the calculated deformation trajectories exhibit excellent fitting with the experimentally collected data, with an average difference between the two of less than 0.3 mm, validating the accuracy of the suspended beam deformation model. Based on the statistical findings, the maximum average deformation of the uncompensated sample is approximately 5.20 mm, whereas the maximum deformation of the sampled point after compensation measures around 0.15 mm. Consequently, the maximum deformation of the printed sample post-compensation is mitigated to roughly 3% of its pre-compensation magnitude. The proposed method in this paper was applied to the repair experiment of damaged curved surface components. A comparison was made between the point cloud data of the repaired surface and the ideal model of the component, with the average distance between them serving as the repair error metric. The mean distance between the point clouds of the repaired parts using the proposed repair strategy is 0.197 mm and the intact model surface is noticeably less than the mean distance corresponding to direct repair, at 0.830 mm. The repair error with compensatory support beams was found to be 76% lower than that without compensatory support beams. The surface without compensatory support beams exhibited gaps, while the surface with compensatory support beams appeared dense and complete. Experimental results demonstrate the effectiveness of the proposed method in significantly reducing the geometric errors in the repaired structural parts. The outcomes of the FDM repair method are validated through these experiments, affirming its practical efficacy. It is noteworthy that, although only PLA material was used in this study, the proposed method is general and effective for other polymer materials. This holds the potential to significantly reduce costs for the remanufacturing of widely used polymers.

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Section: Introductionmentioning

confidence: 99%

Enhancing Additive Restoration of Damaged Polymer Curved Surfaces through Compensated Support Beam Utilization

Zhang,

Guo

2024

Processes

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“…The AFS-D process has been used for fabricating parts with different types of materials. The focus is mostly on aluminum alloys [2][3][4][5][6][7][8][9] in the literature due to their low melting point. However, other materials including nickel alloys [10,11], titanium alloys [12], magnesium alloys [13], copper [14,15], and steel [16,17] have also been processed.…”

Section: Introductionmentioning

confidence: 99%

“…However, other materials including nickel alloys [10,11], titanium alloys [12], magnesium alloys [13], copper [14,15], and steel [16,17] have also been processed. Other than fabricating new parts, AFS-D has been shown to be effective in recycling [12,18] and reparation [9] as well.…”

Section: Introductionmentioning

confidence: 99%

Neutron Imaging of Al6061 Prepared by Solid-State Friction Stir Additive Manufacturing

Nemati

Butler

Ham

et al. 2023

Metals

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Solid-state Friction Stir Additive Manufacturing has recently gained attention as a result of its capacity to fabricate large-scale parts while preserving the mechanical properties of the feedstock material. However, the correlation between the quality of layer-by-layer bonding of the deposited metal and processing parameters has remained unknown. Neutron imaging techniques, with 90% total transmission per cm, are employed for Al6061 parts fabricated by MELD® Technology as a non-destructive evaluation approach for the first time to investigate the layer-by-layer structure of a stadium-shaped ingot in different sections. The post-processed results show the fabricated parts with an optimized set of processing parameters are void-free. However, the hydrocarbon-based feedstock lubricant segregates between the layers, which consequently may lead to non-uniform weaker mechanical properties along the build direction and stimulate crack initiation during mechanical loading. The tensile test results show 14% lower strain-to-failure values in alleged contaminated areas in transmission imaging results. Additionally, layer bonding is significantly impacted by hot-on-hot and hot-on-cold layer deposition schemes, especially for larger layer thicknesses.

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“…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.…”

Section: Introductionmentioning

confidence: 99%

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

Stubblefield

Williams

Munther

et al. 2022

J. dynamic behavior mater.

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In this work, Additive Friction Stir Deposition (AFSD) was employed for ballistic repair of AA7075-T6511 plates. After penetration with 7.62 × 51 mm FMJ rounds, the AA7075-T6511 plates were repaired by AFSD using the same AA7075-T6511 feedstock material. The repaired plates were impacted and penetrated with the same 7.62 × 51 mm FMJ rounds, and the surface damage characteristics including the initial and residual velocities were compared against the control wrought plates. The AFSD process successfully repaired the damaged control plates with the same alloy, without any observable defects such as large cracks or pores prior to impact tests. Although the surface appeared pristine other than milling marks, the surface damage characteristics of the repaired plates were significantly different than the control plates. The increase of spalling and petalling with the repaired material can be attributed to the thermomechanical processing of AFSD, which would alter the control T6511 temper of the feedstock due to coarsening of strengthening precipitates. A cross-sectioned repaired plate was analyzed using microhardness plots and optical microscopy to illustrate the effectiveness of the AFSD process for ballistic repair by depositing the same material into the damaged area. Despite the surface damage discrepancy, the repaired plates performed similarly to the control plates with respect to initial and residual velocities. Graphical Abstract

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Repair of aluminum 6061 plate by additive friction stir deposition

Cited by 30 publications

References 32 publications

Enhancing Additive Restoration of Damaged Polymer Curved Surfaces through Compensated Support Beam Utilization

Enhancing Additive Restoration of Damaged Polymer Curved Surfaces through Compensated Support Beam Utilization

Neutron Imaging of Al6061 Prepared by Solid-State Friction Stir Additive Manufacturing

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

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