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Meeting 2025 TMS Annual Meeting & Exhibition
Symposium Friction Stir Welding and Processing XIII
Presentation Title Force Feedback and Bonding Characteristics of Graphite Free Aluminum 7075 using Additive Friction Stir Deposition
Author(s) Jacob Hansen, Luk Dean, Yuri Hovanski, Michael Merrell
On-Site Speaker (Planned) Jacob Hansen
Abstract Scope Additive Friction Stir Deposition (AFSD) is a solid state bulk metal additive manufacturing process. It's often considered a derivative technology of Friction Stir Welding. Previous work with regards to 7075 Aluminum has been done using graphite or other lubricants. Graphite contamination within AFSD parts is undesirable. We have demonstrated the ability to successfully deposit multiple layers of 7075 Aluminum with AFSD that are completely graphite free. As part of the graphite free solution, we have had to make modifications to our AFSD machines and our printing process. By doing so, we have been able to print layers with a steady state force of around 22kN; with forces dropping as low as 18-19kN for some layers. Initial evaluation via optical microscopy has indicated strong bonding characteristics between graphite free layers. We are pushing to produce fully consolidated AFSD parts that are repeatable and consistently free from graphite or other contaminating lubricants.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Aluminum, Process Technology

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Comparative Study of an Ambient and Underwater Graphite Free Repair of Aluminum Alloy 7050 by Additive Friction Stir Deposition
A Discontinuous Dynamic Recrystallization Model for Predicting Grain Features during Friction Stir Processing
A New Method of Tool Depth Control in Friction Stir Welding
A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles
A Review of Friction Stir Welding Focused Path Planning
A Solid-State Additive Manufacturing Approach for the Fabrication of SiC-Reinforced Metal Matrix Composite in Automotive Components of Light Metal
Achieving Uniform Extrudate and Homogeneous Microstructure in Friction Extrusion
Additive Friction Stir Deposition of Carbon Steel
Advanced Strengthening of Austenitic Manganese Steel via Friction Stir Processing and Subsequent Work Hardening
Advancements for Thick Titanium FSW
Advancements in Lubrication-Free Additive Friction Stir Deposition and Post-Processing Heat Treatments for Aluminum Alloys
Advances in Meshfree Simulations of Friction Stir Welding and Processing
AFSD Temperature and Stress Modeling
Analysis of FSW Macro-Sections in Aluminum Relative to Unit-Area Data Features
Characterization of an Alternative Solid-State Additive Manufacturing Process
Characterizing Welds and Parameters of Ultra-High-Speed Friction Stir Welding in the Lap Welding Configuration
Computational Framework for the Accurate and Efficient Simulation of FSW Processes
Deposition Parameters & Property Correlations in Novel Al-Ce Alloys
Designing Tools for Graphite Free Additive Friction Stir Deposition
Developing AFSD Processes for Critical Aviation and Defense Applications
Development of copper CoreFlow® friction stir channelling for fusion energy applications
Development of High-Speed Double-Sided Friction Stir Welding Technology with Optimized Pre-Heating Process for Automotive Advanced High Strength Steels
Development of novel friction surfacing method
EBSD Analysis of AA7075-T6 Thin Sheets Butt Joints Obtained by Impulse Friction Stir Welding
Effect of Layer Thickness on Resulting Microstructures and Mechanical Properties of Aluminum Alloys Using Additive Friction Stir Deposition
Effect of Multiple-Pass Friction Stir Processing on Microstructural and Mechanical Properties of Stir Cast AA5083-2wt.%SiC Nanocomposite
Effect of processing parameters on the microstructure and mechanical properties in friction stir consolidated ODS-14YWT powders
Effect of Tool Geometry on Process Forces for FSW in Stainless Steel
Effect of welding speed on tensile shear strength of friction stir lap weld of wrought AA5052 to die-cast A383
Evaluation of Additive Friction Stir Deposited A206
Fabrication of laminated metal composites using additive friction stir deposition
Flexible ultrasonic-enhanced friction stir welding
Force Feedback and Bonding Characteristics of Graphite Free Aluminum 7075 using Additive Friction Stir Deposition
Friction Self-Piercing Riveting Process for 3T Configuration of AA7075-AA7075-AA6022
Friction Stir Butt-Lap Welding of Aluminum to Steel: A New Joint Design to Improve Mechanical Properties
Friction Stir Lap Welding for High-strength Aluminum Automotive Components
Friction Stir Polymer Bonding of AA6061 and Beech Wood
Friction Stir Processing of 316L Stainless Steel for Improvements in Biomedical Application
Friction stir welding of Haynes 282 Ni-based super alloy by using a novel hemispherical tool
Heat Treatment of Multitrack Friction Stir Processing of Precipitation Hardenable Aluminum Alloy
Hybrid Repair Techniques for Heat-treatable Aluminum Alloys
Improvement of Microstructure and Mechanical Performance of Wire Direct Energy Deposited Maraging 250 Steel by Friction Stir Processing
Improving Build Direction Heat Treated Tensile Properties of Additive Friction Stir Deposition AA7050
Industrial production of thick-walled and highly loaded aluminium structures for railroad applications with FSW
Influence of Friction Stir Welding on the Corrosion Resistance of Al6061
Integrating MegaStir Liquid-Cooled Tool Holder with MELD L3 Machine: Purpose and Process
Lightweight Bimetallic Tubular Components Via Friction Stir Backward Extrusion: Fabrication and Process Outcome Analysis
Machine Learning Based In-process Defect Detection in Refill Friction Stir Spot Welding
Machine Learning Implementations for Predicting Weld Strengths on Aluminum 7075
Measurement of heat transfer coefficient between a friction stir welding tool and workpiece during plunge using a 3-omega sensor
Metal matrix composites of Al/Al2O3 obtained via friction stir processing
Mitigating Solidification Cracking in Dissimilar Metal Welds (Mild Steel to Dual Phase Stainless Steel)
On the flexibility of feedstock, process, and microstructure control in solid-phase metal deposition via SolidStir®-AM
Optimizing Hardness in the Heat Affected Zone of AA7075-T6 Aluminum Alloy via Machine Learning-Guided Friction Stir Welding
Parallel Pass Cladding and Continuous Layer 3D printing of Aluminum 6061-T6 alloy via a Novel Solid-State Additive Friction Extrusion Deposition Additive Manufacturing
Phase-field modeling of grain evolution and recrystallization in friction stir processing
Production of 5 cm Thick Copper Canisters Containing Sweden´s Nuclear Waste Using Friction Stir Welding
Recent advancements in friction-based dissimilar material joining processes for electrical vehicle battery applications: A review aimed towards circular economy and sustainability
Refill Friction Stir Spot Welding in AA6061-T4 Automotive Sheets
Residual Stress in Friction Stir Welded Armor Steel
Scale-Up of Friction Self-Piercing Riveting Process for Multi-Material Joints
Solid-state upcycling of machining chips through additive friction stir deposition
Sustainable Metal Upcycling using SolidStir Extrusion
Temperature and Stresses in AA 6082-T6 Friction Stir Spot Welding (FSSW) Using Coupled Eulerian–Lagrangian Finite Element Method
Temperature Control in Aluminum Friction Stir Applications
The improvement of Corner Stationary Shoulder FSW
The simultaneous double-sided friction stir welding (SDS-FSW) of steel
Towards Achieving Sustainability in Additive Friction Stir Deposition
Two-Layer Build-Up Friction Stir Welding of 6061 Aluminum Alloy Using Externally Supplied Bulk Material
Vibration Diagnostics Regulated Automatic Friction Stir Processing
Visual Temperature Estimation and Flash Detection of Aluminum 7075 Welds Using Neural Networks

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