Wire-Based Friction Stir Additive Manufacturing toward Field Repairing

CHEN, HUIZI; Chen, Jialin; Meng, Xianghai; Xie, Yuming; Huang, Yongxian; XU, SHUANGMING; Zhao, Yaobang

doi:10.29391/2022.101.019

Cited by 13 publications

(3 citation statements)

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“…Apart from the MLFS technique, there are other solid-state AM approaches based on the combination of friction and plastic deformation. These include additive friction stir deposition (AFSD) [23] or wire-based friction stir additive manufacturing (W-FSAM) [24], both closely related to the FS principle, where these techniques offer continuous feeding of the consumable material to be deposited. However, in contrast to FS, these processes require tooling to process the material.…”

Section: Introductionmentioning

confidence: 99%

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Rath

Kallien

Roos

et al. 2023

Int J Adv Manuf Technol

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Friction surfacing (FS) is a solid-state layer deposition process for metallic materials at temperatures below their melting point. While the bonding of the deposited layers to the substrate is proven suitable for coating applications, so far the mechanical properties of additively manufactured stacks have not been systematically investigated. In particular, the effect of successive deposited FS layers, i.e., repetitive thermo-mechanical loading, on the interface properties as well as anisotropy and strength of the deposited stack is unknown. For this purpose, the mechanical properties of FS deposited multi-layer stacks from dissimilar aluminum alloys have been investigated, characterizing layer-to-layer as well as layer-to-substrate bonding interfaces via micro-flat tensile testing. Furthermore, directional dependencies in the stack and failure mechanisms are analyzed. The results show a homogeneous, fine-grained microstructure with average grain sizes between 4.2 and 4.6 μ m within the deposited material. The resulting tensile properties with no significant directional dependency present an ultimate tensile strength between 320 and 326 MPa exceeding the strength of the AA5083 H112 consumable base material. No difference was obtained in terms of layer-to-layer or layer-to-substrate interface strength. Furthermore, homogeneous hardness was observed within the deposited structure, which is in the range of AA5083 base material’s hardness of 91 HV. The results indicate that the FS process in conjunction with the material used is suitable for additively generated structures and highlight the potential of this solid-state layer deposition technology.

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Section: Introductionmentioning

confidence: 99%

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Rath

Kallien

Roos

et al. 2023

Int J Adv Manuf Technol

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“…The shear-induced plastic deformation and dynamic recrystallization (DRX), inherent to the AFSD process, produces a fully dense, near net-shaped component with a refined microstructure consisting of a homogenous grain structure exhibiting forged-like mechanical performance. The AFSD process is a versatile AM method that can utilize multiple feedstock avenues such as the solid bar [22], machine chips [23], and wire [24,25].…”

Section: Introductionmentioning

confidence: 99%

Towards Understanding the Relationships between Processing Conditions and Mechanical Performance of the Additive Friction Stir Deposition Process

Williams,

Zhu,

Palya

et al. 2023

Metals

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In this research, we explore the preliminary effects of processing conditions using a novel additive manufacturing (AM) process, known as additive friction stir deposition (AFSD), on resulting build direction (BD) mechanical performance. Using the AFSD process, a feasibility study of three AM builds of identical size are created using differentiating processing parameters. A relationship referred to as the deposition pitch, exhibiting similarities to weld pitch, is determined to be a simple but effective predictor of the interlayer bonding in AFSD processing of AA7020. The deposition pitch directly correlates the necessary temperature, time, and pressure required for effective solid-state bonding. Using this correlation, increased mechanical performance in the BD is achieved through an increase in deposition pitch. A reduction in the deposition pitch from 4.46 rev/mm to 1.08 rev/mm resulted in a significant decrease in failure strain from 24.4% to 0.82%, with the failure mechanism shifting from a ductile failure to brittle failure. The inverse relationship between grain refinement and BD failure strain at high deposition pitches suggests deposition pitch and heat input are the dominant factors in the resulting BD mechanical properties.

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“…FSW is employed in the extrusion process, called as friction stir extrusion has resulted in high-strength and ductile magnesium alloys [31]. FSW in additive manufacturing areas have proved to be one of the repairing tools which exhibited good performance in the repair aluminium alloy structures [32]. Similar to FSP, FSW has also been employed in the fabrication of ultra-refned grains of composites involving aluminium matrices [33].…”

Section: Introductionmentioning

confidence: 99%

A Contemporary Review on Friction Stir Welding of Circular Pipe Joints and the Influence of Fixtures on This Process

Senthil¹,

Kumar²,

Dennison

2022

Advances in Materials Science and Engineering

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The permanent metal joining processes play a vital role in assembling the complex aluminium structures of the aerospace, automotive, marine, and oil industries. The invention of friction stir welding (FSW) redefined the mechanism of metal joining to produce high-quality welds by eliminating the consumption of electrodes and shielding gases, resulting in economical processes. Research works still lack to explore the application of FSW in complex geometries. In this view, the present work reports a critical review of various geometries welded by FSW, mainly circular geometries that are majorly used in the oil and gas industries. The various aspects of the FSW of pipes, such as process facilitation, process parameters, tool material selection, and tool design selection are discussed. The paper also presents insights into the parameters responsible for the weld quality, the feasibility of optimization techniques, and the status of various fixture arrangements. The facilitation requisites for FSW of pipes are also provided based on the reviews made. The review concludes by discussing the challenges associated with the FSW of pipes, economic aspects, and future research directions.

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Wire-Based Friction Stir Additive Manufacturing toward Field Repairing

Abstract: A new process is introduced for repair of structural components of aluminum alloys. Additive manufacturing, maintenance and repair welding, Al alloy, mechanical properties.

Cited by 13 publications

References 0 publications

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Towards Understanding the Relationships between Processing Conditions and Mechanical Performance of the Additive Friction Stir Deposition Process

A Contemporary Review on Friction Stir Welding of Circular Pipe Joints and the Influence of Fixtures on This Process

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