Friction Stir Welding and Processing XII: Additive Friction Stir Deposition
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Shaping and Forming Committee
Program Organizers: Yuri Hovanski, Brigham Young University; Yutaka Sato, Tohoku University; Piyush Upadhyay, Pacific Northwest National Laboratory; Anton Naumov, Peter The Great St. Petersburg Polytechnic University; Nilesh Kumar, University of Alabama, Tuscaloosa
Monday 8:30 AM
March 20, 2023
Room: 29A
Location: SDCC
Session Chair: Hang Yu, Virginia Polytechnic Institute And State University; Mandana Hendrickson, MELD Manufacturing
8:30 AM Invited
Recent Progress in Additive Friction Stir Deposition: from Process Fundamentals to Niche Applications: Hang Yu1; 1Virginia Polytechnic Institute and State University
Additive friction stir deposition (AFSD) is an emerging solid-state, near-net-shaping technology that integrates the friction stir principle with material feeding to enable location-specific printing and free-forming in 3D space. Although it is still a relatively new process, extensive research efforts in the last few years have propelled AFSD to the forefront of innovation with focused attention from the aerospace, automotive, and defense sectors. In this presentation, I will provide a timely overview of the current development of the process, including insights of the process physics revealed by in situ monitoring, material flow study via time-resolved characterization, dynamic microstructure evolution, and niche applications, such as structural repair, material recycling and upcycling, and selective-area cladding. Future prospects on the development of hierarchical materials and the incorporation of artificial intelligence for process control are also discussed.
8:50 AM Invited
Repair of Railroad Rail via Additive Friction Stir Deposition: Michael Eff1; Kathleen Chou2; Chase Cox3; Connor Saukas2; Jason Carroll2; Ryan Henderson3; 1EWI; 2Eaton; 3MELD Manufacturing Corporation
Repair of rail is challenging using traditional joining methods. Any substantial flaw requires removal and replacement of an entire section of rail. Repairing results in a high residual tensile stress left in the rail, reducing its life and the allowable speed of a train on the rail. This work highlights the development of a repair technique on 1080 carbon steel rail using additive friction stir deposition (AFSD). A simulated flaw was machined out and new material was deposited to restore the rail to its proper geometry. The work examined the effect of various thermal cycles and processing parameters on the quality of the repair as well as the resultant properties of the HAZ via metallography, hardness, and subscale slow bend testing. Through metallurgical modeling coupled with a design of experiment approach, the repair was able to meet the performance criteria for rail repair on subscale specimens.
9:10 AM
Microstructure and Hardness of Al2050 Parts Made by Additive Friction Stir Deposition: Hamed Ghadimi1; Mojtaba Talachian1; Congyuan Zeng1; Huan Ding1; Selami Emanet1; Uttam Bhandari1; Chase Cox2; Michael Eller3; Shengmin Guo1; 1Louisiana State Univ; 2MELD Manufacturing Corporation; 3Lockheed Martin Space
Solid-state additive friction stir deposition (AFSD) process is a high throughput metal 3D-printing technology. The authors investigated various deposition parameters for producing Al2050 pieces using AFSD. The effects of tool’s rotation speed, deposition traverse speed, and the material feed rate on the surface defects and flash of the AFSD parts are discussed and a practical set of deposition parameters are introduced. The microstructural characterization has been performed for various regions of the AFSD parts, and the part’s hardness is also examined along the built-direction.
9:30 AM
Closed-loop PID Temperature Control of Additive Friction Stir Deposition: Jason Glenn1; Luk Dean1; Arnold Wright2; Yuri Hovanski1; 1Home; 2Bond Technologies
Additive friction stir deposition (AFSD), a derivative technology of friction stir welding (FSW) is now rapidly growing in industries that require bulk additive manufacturing. For mass adoption to occur, deposition consistency and quality along with thermal inputs and their impacts need to be better understood and improved. In both AFSD and FSW, it’s been demonstrated that properties of depositions or welds vary along their length in response to in-process temperatures. Research using temperature control to maintain weld temperatures in FSW has been performed for some years now with significant results in both quality and reliability, but this technology is just starting to be applied towards AFSD. This work describes the implementation of a temperature control method that was proven successful in FSW to AFSD. It demonstrates the accuracy achievable using that method for AA 7050 T7451, compares the controlled results against a fixed RPM deposition, reviews results of temperature control over multi-pass AFSD, and outlines future work for AFSD involving temperature control.
9:50 AM Break
10:10 AM Invited
Advancement of US Navy Sustainment Capabilities Through Solid-State Additive Manufacturing (FSW/FSAM): Stephen Cox1; 1U S Navy
Researchers at the U.S. Naval Information Warfare Center in San Diego are tasked with leveraging next-generation technologies, such as Frictional Stir Additive Manufacturing, a follow on to FSW, to increase sustainment capabilities in support of the modern warfighter. In this presentation the author will outline three specific applications of the FSW/FSFAM process; 1) the 3D printing of long-lead raw casting replacements, 2) the repair of legacy components currently without a repair strategy, and 3) Navy patented approach for significantly extending the life of new/legacy components by depositing/embedding a sacrificial anodic material directly onto a targeted area of the component’s geometry. The FSAM process is a solid-state metal additive technology that utilizes a non-consumable rotating tool to plastically deform solid, wrought bar feedstock, as means to enable both additive manufacturing, joining, and repair of large metal components. Will include results of latest release September 2022.
10:30 AM
A Feasibility Study on Friction Screw Extrusion Additive Manufacturing of AA6060: Ton Bor1; Sharon Strik1; Saed Sayyad Rezaeinejad1; Nick Helthuis1; Bert Vos1; Martin Luckabauer1; Remko Akkerman1; 1University of Twente
Additive manufacturing in the solid state opens up possibilities for many alloys that are not suitable for fusion-based approaches. Following the advances in friction-based joining processes for high-strength aluminium and magnesium alloys, the Friction Screw Extrusion Additive Manufacturing (FSEAM) process has been developed for deposition of thin layers for cladding and additive manufacturing on a variety of substrates. In this work the first results on the manufacturing of wall-like rectangular builds from AA6060T6 are reported. Multiple layers of about 15 mm width and 1 mm thickness were deposited with print velocities of 100 mm/min to 250 mm/min at constant tool rotation speed. Solid walls were formed without major macroscopic defects. Promising mechanical properties were measured with a yield strength of about 80 MPa and a tensile strength increasing from 112 to 144 MPa as function of the print velocity. The material was characterized by a fine microstructure with an average grain size below 10 μm for all builds. At the microscale strings of unbonded regions have been observed at lower print velocities possibly related to insufficient mixing of the deposited material with the previous layer during manufacturing leading to reduced ductility.The observed results are encouraging, indicating that additive manufacturing of aluminium alloys through FSEAM is feasible after further optimization of the process.
10:50 AM
Fundamental Study of Material Properties of Aluminum Additively Manufactured via Multi-layer Friction Surfacing: Zina Kallien1; Lars Rath1; Arne Roos1; Benjamin Klusemann1; 1Helmholtz-Zentrum Hereon
Friction surfacing (FS) is a solid-state layer deposition technology applicable for various similar and dissimilar metallic materials. The potential is not limited to single layer coatings, since multiple layers on top of, i.e. multi-layer friction surfacing (MLFS), and adjacent to each other, i.e. multi-track friction surfacing (MTFS) are possible. In order to use the FS process variants as solid-state additive manufacturing technology, the metallurgical and microstructural composition as well as mechanical performance of the deposited structures need investigation. The deposited material exhibits refined grains and homogeneous microstructure. Extensive characterization of the mechanical properties using micro-flat tensile testing revealed no significant gradients at strength values in the range of base material. Additional inherent advantages of this technology, e.g. low heat input, slight distortion, further underline the potential of FS. Fundamental understanding of MLFS material properties will significantly contribute to the technology’s further development and application as prospect solid-state additive manufacturing technique.
11:10 AM Invited
Neutron/X-ray Testing on Al6061 Prepared by Solid-state Friction Stir Additive Manufacturing: Saber Nemati1; Les Butler1; Gerry Knapp2; Kyungmin Ham1; Selami Emanet1; Hamed Ghadimi1; Congyuan Zeng1; Shengmin Guo1; 1Louisiana State University; 2Oak Ridge National Laboratory
Solid-state Friction Stir Additive Manufacturing has recently gained attention as a result of its capacity to fabricate large-scale parts while preserving mechanical properties of the feedstock material. However, the correlation between the quality of layer-by-layer bonding of the deposited metal and processing parameters has remained unknown. Neutron and X-ray imaging techniques are employed for Al6061 parts fabricated by MELDŽ Technology as a non-destructive evaluation approach to investigate the layer-by-layer structure of a MELD part in different sections. The post-processed results show the fabricated parts with an optimized set of processing parameters are void-free. The local temperature effect during fabrication was detected by Neutron/X-ray testing.