| Abstract Scope |
The repair of high-value metallic components in aerospace, defense, and transportation is increasingly vital for sustainability, cost savings, and extended service life. Traditional fusion-based methods often introduce defects such as porosity, residual stress, and cast microstructures. SolidStir® Additive Manufacturing (AM), a solid-state, friction stir-based technique, offers a superior alternative for structural repair. This study explores the use of SolidStir® AM for repairing aluminum alloy components, focusing on microstructural integrity and mechanical performance. The process uses a rotating tool to plastically deform and deposit feedstock in solid state, eliminating melting-related issues. Microstructural and mechanical evaluations show that repaired zones match base material performance. Case studies demonstrate effective restoration of geometry and mechanical properties. SolidStir® AM enables localized, cost-efficient repairs, reduces material waste, and supports energy-efficient manufacturing. Its potential for in-situ repair applications further enhances its value for resource-limited maintenance operations. |