“…AFSD further adds to the advantages of FSAM by enabling fabrication of large structures with relatively higher geometrical complexities [25][26][27] . AFSD has been explored for AM of conventional non-ferrous [28][29][30][31] and ferrous [32] alloys. One of the earliest papers demonstrated successful AFSD of aluminum 2024 alloy much before advent of MELD® technology [33] .…”
“…AFSD further adds to the advantages of FSAM by enabling fabrication of large structures with relatively higher geometrical complexities [25][26][27] . AFSD has been explored for AM of conventional non-ferrous [28][29][30][31] and ferrous [32] alloys. One of the earliest papers demonstrated successful AFSD of aluminum 2024 alloy much before advent of MELD® technology [33] .…”
“…Microstructure consists of both α and β phases with a variation in prior β grain size from top to bottom as shown in Figure 11(b). Figure 11 (a) Image of additive friction stir deposited Ti64, and (b) backscattered images of Ti64 from the plane parallel to build direction [37]. …”
Section: Examples Of Applicability Of Fsam and Afsd To Various Alloysmentioning
confidence: 99%
“…(a) Image of additive friction stir deposited Ti64, and (b) backscattered images of Ti64 from the plane parallel to build direction [37]. …”
Section: Examples Of Applicability Of Fsam and Afsd To Various Alloysmentioning
Additive manufacturing (AM) has completely altered the traditional component manufacturing and qualification paradigm. It provides unitisation and topological optimisation opportunities simultaneously. Broadly, the additive manufacturing processes are classified as fusion-based or solid-state. The solid-state additive manufacturing processes are relatively nascent. Among these, friction stir-based processes involve intense shear deformation of material while building. In this review, we focus on friction stir additive manufacturing (FSAM) and additive friction stir deposition (AFSD). These friction stir welding derived techniques have ability to produce microstructures that lead to better mechanical properties than the conventionally processed parent alloys; in many cases overcoming the traditional strength-ductility tradeoff paradigm. The best way to capture this advantage is to conduct materials selection for build which benefit from the attributes of these processes. This review provides a systems approach framework and a conceptual process model to guide researchers. A case is built that the best mechanical properties can be obtained by alloy design for such disruptive and innovative manufacturing processes. The intrinsic and extrinsic limitations are highlighted to guide researchers in the field of FSAM and AFSD. While AFSD is readily applicable to lower melting temperature materials currently, applying it to high-temperature materials requires significant research and development on tool materials. Examples of materials processed by FSAM/AFSD include aluminium alloys, magnesium alloys, titanium alloys, steels and nickel-base superalloy. A physics-based process modelling framework applicable to FSAM/AFSD is provided. To fully validate such models, it is imperative to use machines with appropriate sensors that capture the machine parameters, tool health, and workpiece temperature.
“…A feasibility investigation on applying AFS-D to prepare Al matrix composites was also performed, and Al-SiC, A6061-Mo, and Al6061-W composites were made, showing homogeneous particle distribution without porosity [ 26 ]. In addition to Al alloys, other alloys with higher melting temperatures have also been fabricated and investigated with AFS-D processes, i.e., Inconel 625 alloy [ 27 ], Ti-6Al-4V alloy [ 28 ], stainless steel 316 L [ 29 ], and Cu 110 [ 30 ].…”
In this paper, the phase structure, composition distribution, grain morphology, and hardness of Al6061 alloy samples made with additive friction stir deposition (AFS-D) were examined. A nearly symmetrical layer-by-layer structure was observed in the cross section (vertical with respect to the fabrication-tool traversing direction) of the as-deposited Al6061 alloy samples made with a back-and-forth AFS-D strategy. Equiaxed grains were observed in the region underneath the fabrication tool, while elongated grains were seen in the “flash region” along the mass flow direction. No clear grain size variance was discovered along the AFS-D build direction except for the last deposited layer. Grains were significantly refined from the feedstock (~163.5 µm) to as-deposited Al6061 alloy parts (~8.5 µm). The hardness of the as-fabricated Al6061 alloy was lower than those of the feedstock and their heat-treated counterparts, which was ascribed to the decreased precipitate content and enlarged precipitate size.
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