A Perspective on Solid-State Additive Manufacturing of Aluminum Matrix Composites Using MELD

Griffiths, R. Joey; Perry, Mackenzie E. J.; Sietins, Jennifer M.; Zhu, Yunhui; Hardwick, Nanci; Cox, Chase; Rauch, Hunter A.; Yu, Hang

doi:10.1007/s11665-018-3649-3

Cited by 90 publications

(46 citation statements)

References 51 publications

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“…In order to repair various types of volume damages in AA 7075-including keyholes, long grooves, large-scale corrosion or wear damages-it is vital to develop a versatile solid-state technique that can continuously supply filler material, while also allowing for digital control of the material addition and repair paths. Such a technique remained elusive until the recent emergence of a solid-state metal additive manufacturing technique-additive friction stir deposition [24][25][26]. Additive friction stir deposition integrates the friction stir principle with a robust material feeding mechanism to enable site-specific deposition.…”

Section: Introductionmentioning

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: Introductionmentioning

confidence: 99%

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

et al. 2019

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“…Figure 1 illustrates the AFSD principle with a comparison to alternative additive processes, including ultrasonic additive manufacturing, cold spray additive manufacturing, and powder bed fusion. We note that in addition to solid rod, powder feedstock can be used as the feed material in AFSD, which involves a different tool head design based on an auger conveyor [34,37].…”

Section: Printing By Deformingmentioning

confidence: 99%

“…More importantly, the deformation state in AFSD is predominantly characterized by compression and shear, which effectively eliminates potential internal defects during printing. Even if the feed material is not fully dense, the as-printed material can be free of porosity thanks to the intense material deformation and flow under the tool head [34,37].…”

Section: Porositymentioning

confidence: 99%

“…First, ultrasonic additive manufacturing is a hybrid technology based on initial ultrasonic welding of foils followed by CNC (computer numerical control) machining, whereas AFSD is a freeform fabrication process that enables printing at specific locations. Second, cold spray additive manufacturing often leads to incompletely bonded interfaces between particles, resulting in porosity and micro-cracks [32,33]; in contrast, AFSD typically renders fully-dense parts in the as-printed state [30,34]. Third, while ultrasonic additive manufacturing, cold spray additive manufacturing, and AFSD are all based on deformation bonding, the former two only involve local plastic deformation around the interface or particle contact regions.…”

Section: Introductionmentioning

confidence: 99%

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

Mishra

2020

Materials Research Letters

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115

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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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“…The mixture of two proper materials in the production of many composites has widely been used [28][29][30][31][32][33][34][35]. Mixed material has been detected to be effective in the 3D printing by a known approach, such as FDM.…”

Section: Experimental Workmentioning

confidence: 99%

The Synergic Effects of FDM 3D Printing Parameters on Mechanical Behaviors of Bronze Poly Lactic Acid Composites

et al. 2020

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In this paper, the influence of layer thickness (LT), infill percentage (IP), and extruder temperature (ET) on the maximum failure load, thickness, and build time of bronze polylactic acid (Br-PLA) composites 3D printed by the fused deposition modeling (FDM) was investigated via an optimization method. PLA is a thermoplastic aliphatic polyester obtained from renewable sources, such as fermented plant starch, especially made by corn starch. The design of experiment (DOE) approach was used for optimization parameters, and 3D printings were optimized according to the applied statistical analyses to reach the best features. The maximum value of failure load and minimum value of the build time were considered as optimization criteria. Analysis of variance results identified the layer thickness as the main controlled variable for all responses. Optimum solutions were examined by experimental preparation to assess the efficiency of the optimization method. There was a superb compromise among experimental outcomes and predictions of the response surface method, confirming the reliability of predictive models. The optimum setting for fulfilling the first criterion could result in a sample with more than 1021 N maximum failure load. Finally, a comparison of maximum failure from PLA with Br-PLA was studied.

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A Perspective on Solid-State Additive Manufacturing of Aluminum Matrix Composites Using MELD

Cited by 90 publications

References 51 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

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

The Synergic Effects of FDM 3D Printing Parameters on Mechanical Behaviors of Bronze Poly Lactic Acid Composites

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