| Abstract Scope |
Additive friction stir deposition, or AFSD for short, is an emerging solid-state additive process that can provide wrought-like characteristics in high strength 7xxx Al. Ongoing research from Virginia Tech has shown that through-holes in AA7050 plates can be repaired with the post-repair fatigue life better than the bushing approach, nearly meeting undamaged fatigue life standards. To better understand how the AFSD repair process is governed by the repair strategy and repair geometry, a test matrix involving various repair dimensions and strategies has been conducted with the process physics comprehensively investigated via an integrated in situ monitoring platform. Clear physical trends are unraveled for the AFSD process fundamentals with important thermal and mechanical insights. With the temperature scaling patterns and printer feedback patterns revealed and correlated to the repair behavior, this work lays the foundation for understanding process physics linkages and component-level effects from AFSD repairs. |