| Abstract Scope |
As demand for high-performance aluminum components accelerates, traditional forging and casting methods are increasingly constrained by long lead times, limited capacity, and supply chain volatility. Additive Friction Stir Deposition (AFSD), a solid-state additive manufacturing process, presents a transformative alternative, using significantly less energy and offering lower costs than forgings for low- to medium-volume production.
This work summarizes recent trials using a modified high-force AFSD system, achieving deposition rates exceeding 100 lbs/hr in AA6061 with flaw-free builds and yield strengths above 40 ksi. Microstructural analysis revealed extensive interlayer mixing and fine equiaxed grains, typical of solid-state processing. The feedstock was as-extruded AA6061 square bar, with no lubricants or surface treatments applied. These results confirm that high deposition rates can be achieved without compromising performance. With near-100% feedstock utilization, unmatched throughput, and compatibility across aluminum alloys, AFSD is enabling faster, flexible, and more sustainable aluminum production for critical applications. |