| Abstract Scope |
To attain significant enhancements in material performance for critical applications like hypersonic travel and deep-sea exploration, it is imperative to employ non-conventional materials processing techniques, especially those under far-from-equilibrium conditions, which can lead to novel phases and microstructures along with unprecedentedly excellent properties. However, few non-equilibrium processing techniques enable large-scale manufacturing for structural applications due to constraints in quench rate and consolidation. Here, we introduce a large-scale deformation-based additive manufacturing technology, additive friction stir deposition, and demonstrate its promise for scalable non-equilibrium processing. Characterized by extreme thermomechanical processing conditions, the feed material undergoes rapid and severe plastic deformation (peak strain rate > 100/s; total strain >10) at elevated temperatures (70%-90% melting temperature) during additive manufacturing. This can lead to interesting kinetic phenomena on the component level, such as shear-induced mixing and element segregation, enabling salient changes in solid solubility, microstructure and mesostructure formation, and material responses to external stimuli. |