Abstract Scope |
Additive friction stir deposition is a novel solid-state metal additive manufacturing process that enables the cladding and repair of lightweight aluminum structures with low energy, low cost, and low residual stresses. Based on repaid plastic deformation at elevated temperatures, the deposited material and base material are co-plastically deformed and mixed, resulting in strong bonding with a gradient interface. In this presentation, we show examples of dissimilar material cladding on 6xxx aluminum automotive sheet metals as well as structural repair of high strength 7xxx aluminum. Excellent post-cladding and post-repair mechanical performance are achieved, in which good interface quality plays a key role. We also explore the effects of thermo-mechanical processing on the temper and microstructure of the base material, which helps us advance our modeling efforts to better predict the static and fatigue performance of the resulting aluminum structures. |