Solid-state cladding on thin automotive sheet metals enabled by additive friction stir deposition

Hartley, W. Douglas; García, David; Yoder, Jake K.; Poczatek, Eric; Forsmark, Joy; Luckey, S. George; Dillard, David A.; Yu, Hang

doi:10.1016/j.jmatprotec.2021.117045

Cited by 70 publications

(18 citation statements)

References 36 publications

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“…As shown in Figs. 4c, e and g, the microstructural changes in the upper and lower middle part of the cross-section of deposition, and the edge of the deposition are obvious, and ne equiaxed grains are observed in these three regions, indicating that DRX occurred during the deposition process, the results of this study are consistent with the ndings of previous research [17,33,43,44]. Comparing the EBSD maps of the center top and bottom, the grain size of the former is larger than that of the latter, which may be due to the higher frictional heat generation between the deposited material and the tool head, while a possibility cannot be ruled out that the top contact with air and the bottom contact with metal, so the heat dissipates more slowly at the top and the top shows grain growth at a higher temperature.…”

Section: Microstructure Evolutionsupporting

confidence: 91%

“…It was found that for thin substrates for automotive use, geometry of the tool determines the cladding quality, and that at tools are more bene cial to develop good cladding quality. Although the protruding tool facilitates material ow and interfacial bonding, this can easily penetrate the substrate and a thicker deposition layer must be taken to avoid scratching the substrate, which in turn can lead to insu cient deformation of the deposited material to affect the cladding quality [34].…”

Section: Introductionmentioning

confidence: 99%

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

Shen

Zhang

Li³

et al. 2023

Int J Adv Manuf Technol

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This work investigates microstructure characterization and mechanical properties of Aluminum alloy fabricated by additive friction stir deposition (AFSD). Microstructure characterize of the Aluminum alloy 5B70 base material (BM) and build were compared using optical microscope (OM) and electron back scattered diffraction (EBSD). Hardness distribution in the direction perpendicular to the cross-section of deposited area was measured and the pattern was evaluated. Tensile tests were performed on the BM and the deposition using digital image correlation (DIC), and the stress distribution states of the specimens were analyzed in real time. After the tensile tests, the fracture micromorphology was characterized using scanning electron microscope (SEM). The results show that a high degree of recrystallization of the grains in the deposition zone occurs and ne equiaxed grains are formed, which are oriented differently. In tensile tests on the deposition, it was found that the strength of the deposition was signi cantly lower compared to the BM, but its toughness was signi cantly higher. And there is a signi cant anisotropy in the mechanical properties of the deposition.

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Section: Microstructure Evolutionsupporting

confidence: 91%

Section: Introductionmentioning

confidence: 99%

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

Shen

Zhang

Li³

et al. 2023

Int J Adv Manuf Technol

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“…AFSD is advantageous for repairing thicker parts with deep damage: the forces and heat buildup during deposition result in extensive material flow with macroscopic material mixing across the interface. , Figure e shows how AFSD is used to fill a through-hole (6.35 mm or 1/4 in. in diameter) in a 6.35 mm (1/4 in.)…”

Section: Evaluation Of Repair Capabilities Based On Key Metricsmentioning

confidence: 99%

“…AFSD can also print large-scale complex parts like domes and tubes, allowing for internal overhangs of up to 54° . Using specific tooling and approaches, it is even possible to clad on thin automotive sheet metals without local distortion or wrinkling …”

Section: Evaluation Of Repair Capabilities Based On Key Metricsmentioning

confidence: 99%

Solid-State Metal Additive Manufacturing for Structural Repair

et al. 2021

Self Cite

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Metrics & MoreArticle Recommendations CONSPECTUS: Structural metal components play a vital role in a broad range of industries, from aerospace and automotive to infrastructure and defense. In service, these components can experience substantial wear, thermal fatigue, erosion, corrosion, or chemical reactions, resulting in significant surface or even volumetric damages. Replacement of these components is often energy-intensive and economically impractical. Structural repair, which aims to restore the original geometry while enabling good mechanical performance postrepair, can offset the costs dramatically. Depending on the additive capabilities and bonding mechanisms, structural repair technologies can be divided into four categories: nonadditive, nonmelting-based; nonadditive, melting-based; additive, nonmelting-based; additive, melting-based. Although melting-based approaches can be applied to various repair geometries with good precision, the underlying melting and solidification processes inevitably lead to crucial problems impacting the mechanical performance, such as solidification porosity, high residual stresses, dendritic microstructure formation, elemental segregation, hot cracking, and stress corrosion cracking. To fundamentally solve or minimize these problems, one may employ solid-state technologies that leverage ultrasonic vibration, friction stirring, or particle impact to facilitate metallurgical bond formation. For robust geometry restoration, an additive capability needs to be incorporated for continuous material feeding and precise deposition path control. Currently, two solid-state technologies satisfy the requirement, cold spray and additive friction stir deposition.In this Account, we discuss the structural repair enabled by solid-state metal additive manufacturing, focusing on (i) cold spray, which is a relatively established process, and (ii) additive friction stir deposition, which is an emerging process recently triggering significant research effortsthe authors are particularly invested in this process and are pioneering the research on process fundamentals and structural repair applications. In cold spray, a substrate is bombarded with small metal particles at high speed; upon impact, the particles and substrate co-deform, resulting in interfacial bonding and mechanical interlocking. In additive friction stir deposition, frictional heat is created after the rapidly rotating feed-rod contacts the substrate, followed by co-plastic deformation and mixing between the deposited material and substrate surface. This renders a strong interface with complex 3D features. Both cold spray and additive friction stir deposition can be applied to a wide range of repair geometries while preventing hot cracking and high thermal exposure. Although cold spray has better portability and spatial resolution than additive friction stir deposition, we believe that additive friction stir deposition is the top choice for repairing load-bearing components given its unparalleled capabilities of rendering equiaxed...

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“…As a result, the plastic is strained and cannot be released before the removal of the constraints. The stiffness and the geometric configuration can greatly influence the expansion and shrinkage of the deposited layers in DED AM [23][24][25]. It is necessary to put forward a new study on the effect of the substrate structure and the constraints on residual stress.…”

Section: Introductionmentioning

confidence: 99%

Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products

Jing

Zhang

et al. 2022

Metals

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A new method of controlling the residual stress in laser directed energy deposition additive manufacturing (DED AM) products proposed based on constraints used in manufacturing and the substrate design. The simulation results of the residual stress, which were validated with the experimental measured data, showed that weaker constraints on the substrate could greatly decrease the residual stress in the laser DED AM products. In addition, by designing local reduced thickness regions into the substrate, such as long strip holes or support legs, the residual stress in DED AM products could be further decreased. In this study, when long strip holes were designed in the substrate, the tensile residual stress was decreased by 28%. An even smaller amount of residual stress was achieved when the design structure was changed to support legs. The tensile residual stress decreased by more than 30%. The fewer support legs, the smaller the residual stress. The residual stress in DED AM products could be well-controlled by design, while the stiffness can be weakened with fewer constraints.

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Solid-state cladding on thin automotive sheet metals enabled by additive friction stir deposition

Cited by 70 publications

References 36 publications

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

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

Solid-State Metal Additive Manufacturing for Structural Repair

Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products

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