About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Alloys: Development and Manufacturing
|
| Presentation Title |
Understanding Al7075/Al6061 Dissimilar Metal Joints Formed Using Additive Friction Stir Deposition |
| Author(s) |
Congyuan Zeng, Patrick Mensah, Kekeli Agbewornu, Edem Honu, Caleb Quantson, Shengmin Guo, Selami Emanet, Huan Ding |
| On-Site Speaker (Planned) |
Congyuan Zeng |
| Abstract Scope |
This study investigates additive friction stir deposition (AFS-D) for joining dissimilar aluminum alloys, Al6061 and Al7075, addressing challenges such as porosity, hot cracking, and weak interfacial bonding found in conventional joining methods. AFS-D leverages mechanical stirring and dynamic recrystallization to enable defect-free, near-net-shape fabrication with minimal post-processing. Two joint configurations were fabricated: Al6061 deposited onto Al7075, and Al7075 onto Al6061 substrates. Comprehensive evaluations included microhardness, microstructural analysis, corrosion testing, thermophysical property assessment, and heat treatment studies. Microhardness testing showed uniform profiles without significant drops, indicating well-bonded joints. EDS mapping confirmed homogeneous elemental distributions with minimal segregation, while heat treatment expanded the interfacial transition layer from ~4 μm to ~100 μm. Solution treatment and aging enhanced joint strength while preserving microstructural integrity. This study demonstrates AFS-D’s effectiveness in producing high-performance dissimilar aluminum joints for aerospace and automotive applications, advancing dissimilar metal joining technologies. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Additive Manufacturing, Aluminum, Joining |