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

Abstract

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.

Optical image and Vickers hardness dataset for repair of 1080 steel using additive friction stir deposition of Aermet 100

“…Additive friction stir deposition (AFSD) was used to deposit Aermet 100 (nominal composition in weight %: 0.21-0.25 C, 11-12 Ni, 13-14 Co, 2.9-3.3 Cr, 1.1-1.3 Mo, Balance Fe) in the machined flaw region as a repair method for the 1080 steel plate. AFSD is a solid-state additive manufacturing process in which feedstock material is passed through a hollow, non-consumable rotating tool head, and frictional heat is generated as the feed material and tool head contact the substrate [2 , 3] . The softened feed material is fed through the tool and metallurgically bonds with the substrate through high shear and severe plastic deformation at the interface [3] .…”

Solid-State Metal Additive Manufacturing for Structural Repair

“…In materials with lower stacking fault energy like copper, discontinuous dynamic recrystallization may play an important role . Because the as-deposited material is fully dense with a fine equiaxed microstructure, the resultant mechanical properties can be comparable to wrought alloys and substantially better than the mechanical properties obtained via fusion-based additive manufacturing …”

“…If volumetric damage needs to be repaired, AFSD can be employed, in which the large tool size and rapid plastic deformation enable a high build rate, on the order of 10 1 kg/hour for steel and aluminum. This allows for efficient printing of large structures; the buildup of aluminum ring structures with a diameter of 3.05 m has recently been demonstrated . As a solid-state process, AFSD can repair both weldable and nonweldable materials with lower energy input and thermal gradients.…”

Microstructural and Mechanical Characterization of Additive Friction Stir-Deposition of Aluminum Alloy 5083 Effect of Lubrication on Material Anisotropy

“…More recently, the solid-state Additive Friction Stir-Deposition (AFS-D) process has been introduced as a low energy, high deposition rate AM technique to deposit a wide range of alloys [17][18][19][20][21]. AFS-D utilizes a non-consumable rotating tool that exploits frictional heat and intense shear stresses to plasticize material as it traverses along a substrate.…”