Microstructure Development in Additive Friction Stir-Deposited Cu

Priedeman, Jonathan L.; Phillips, B.J.; Lopez, Jessica J.; Roper, Brett E. Tucker; Hornbuckle, B.C.; Darling, Kristopher A.; Jordon, J.B.; Allison, P. G.; Thompson, Gregory B.

doi:10.3390/met10111538

Cited by 37 publications

(11 citation statements)

References 37 publications

(80 reference statements)

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“…This technology is a more suitable method to produce metallic parts for the automobile and aircraft industries [1][2][3]. Among the AM techniques [4], friction stir deposition (FSD) is used instead of fusion-based techniques [5] in the manufacturing of aluminum alloys [6,7], copper alloys [8], and steel [9]. This solid-state metal AM technology is based on friction stirring principles [10][11][12], adding a mechanism of material feeding.…”

Section: Introductionmentioning

confidence: 99%

“…Perry et al [24] reported that the AA2024 friction stir deposited at 300 rpm rotational speed, 2 mm/s traverse speed, and feed rate of 0.85 mm/s shows an almost fully recrystallized microstructure. Priedeman et al [8] investigated the microstructure and mechanical properties of AFSD 110 Cu alloy processed at a rotational speed of 275 rpm and a traverse speed of 2.12 mm/s. The results indicated that the microstructure appeared to be recrystallized grains throughout the deposit layers, with different degrees of refinement, and the hardness value revealed that the deposited material was softer than that of the starting feedstock.…”

Section: Introductionmentioning

confidence: 99%

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The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

et al. 2021

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In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect of feeding speeds of 3, 4, and 5 mm/min at a constant rotational speed of 1200 rpm on the macrostructure, microstructure, and hardness of the additive manufacturing parts (AMPs) was investigated. Various techniques (OM, SEM, and XRD) were used to evaluate grain microstructure, presence phases, and intermetallics for the as-cast material and the AMPs. The results showed that the friction stir deposition technique successfully produced sound additive manufactured parts at all the applied feeding speeds. The friction stir deposition process significantly improved the microstructure of the as-cast alloy by eliminating porosity and refining the dendritic α-Al grains, eutectic Si phase, and the primary Si plates in addition to intermetallic fragmentation. The mean values of the grain size of the produced AMPs at the feeding speeds of 3, 4, and 5 mm/min were 0.62 ± 0.1, 1.54 ± 0.2, and 2.40 ± 0.15 µm, respectively, compared to the grain size value of 30.85 ± 2 for the as-cast alloy. The AMPs exhibited higher hardness values than the as-cast A356 alloy. The as-cast A356 alloy showed highly scattered hardness values between 55 and 75.8 VHN. The AMP fabricated at a 3 mm/min feeding speed exhibited the maximum hardness values between 88 and 98.1 VHN.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

et al. 2021

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“…The resultant components exhibit ne equiaxed microstructures that provide enhanced wear resistance, corrosion protection, and mechanical properties [5,21,22]. The rst reported applications of AFSD were for additive manufacturing of aluminum and magnesium alloys [6,7], and additional results were later reported for Inconel 625 [8,9], alloy Ti-6Al-4V [11], copper [10], and aluminum-matrix composites [4]; however, published results for steels are limited [11,-25].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Additive Friction Stir Deposition of AISI 316L For Repairing Surface Material Loss in AISI 4340

Martin

Luccitti

Walluk

2022

Preprint

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Additive technologies provide a means for repair of various failure modes associated with material degradation occurring during use in aggressive environments. Possible repair strategies for AISI 4340 steel using AISI 316L deposited by additive friction stir deposition (AFSD) were evaluated under this research by metallography, microhardness, and wear and mechanical testing. Two repair geometries were investigated: groove-filling and surface cladding. The former represents repair of localized grinding to eliminate cracks, while the latter represents material replacement over a larger area, for example to repair general corrosion or wear. The 316L deposited by AFSD exhibited a refined microstructure with decreased grain size and plastic strain, lower strength, and lower hardness than the as-received feedstock. Wear testing by both two-body abrasion and erosion by particle impingement indicated that the wear resistance of the 316L cladding was as good as, or better than, the substrate 4340 material; however, there was some evidence that the resistance to intergranular corrosion was compromised due to the formation of carbides or sigma phase. In both repair geometries, the microstructure of the substrate beneath the deposited material exhibited heat affected zones that appeared to have austenized during the deposition process, and transformed to martensite or bainite during cooling. This report constitutes an initial evaluation of a novel approach to the repair of structural steel components damaged by microcracking, wear or corrosion.

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“…Similarly, when investigating solid-solution strengthened materials such as Inconel 625, both Rivera et al [31] and Avery et al [17] observed improved mechanical behavior due to significant grain refinement, equiaxed morphologies, and distribution of constituent phases throughout the as-deposited material. Of interest in the AFSD deposition of aluminum, tool wear has been identified in harder alloys such as titanium [30] and Inconel [17] to occur directly along the layer interface, but in softer alloys such as aluminum [18,32,33] and copper [34] there has not been any evidence of tool wear. The decreased wear from these softer alloys is likely a combination of the effect of lower stress on the tool as well as the lower operating temperatures as the deposition temperature has been seen to be a function of the melting point of the feedstock material.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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Additive Friction Stir-Deposition (AFS-D) is a transformative, metallic additive manufacturing (AM) process capable of producing near-net shape components with a wide variety of material systems. The solid-state nature of the process permits many of these materials to be successfully deposited without the deleterious phase and thermally activated defects commonly observed in other metallic AM technologies. This work is the first to investigate the as-deposited microstructure and mechanical performance of a free-standing AA5083 deposition. An initial process parameterization was conducted to down-select optimal parameters for a large deposition to examine build direction properties. Microscopy revealed that constitutive particles were dispersed evenly throughout the matrix when compared to the rolled feedstock. Electron backscatter diffraction revealed a significant grain refinement from the inherent dynamic recrystallization from the AFS-D process. Tensile experiments determined a drop in yield strength, but an improvement in tensile strength in the longitudinal direction. However, a substantial reduction in tensile strength was observed in the build direction of the structure. Subsequent fractographic analysis revealed that the recommended lubrication applied to the feedstock rods, necessary for successful depositions via AFS-D, was ineffectively dispersed into the structure. As a result, lubrication contamination became entrapped at layer boundaries, preventing adequate bonding between layers.

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Microstructure Development in Additive Friction Stir-Deposited Cu

Cited by 37 publications

References 37 publications

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

Evaluation of Additive Friction Stir Deposition of AISI 316L For Repairing Surface Material Loss in AISI 4340

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

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