| Abstract Scope |
Solid-state additive manufacturing (AM) offers safer route for processing magnesium alloys than fusion-based techniques, which often suffer from residual stresses, porosity, and other defects. In addition to these solid-state benefits, use of powder provides greater flexibility for tailoring alloy composition and properties. However, limited ductility of Mg alloys presents challenges for solid-state AM. Solid-state AM technique viz., powder-bed friction stir (PBFS) was employed, and deformation behavior of powder bed was examined with various tools viz., plain (PST), circular (CPF), and spiral-protrusion (SPF). Among various tools CPF with 0.5 mm protrusion height produced 10 mm-thick, defect-free deposit by enhancing inter- and intra-layer material mixing. PBFS process yielded low porosity (~0.04–0.06%) and minimal variation in UTS (~35 MPa) across layers. Residual stress varied between 29.12±3.9 MPa and 21.32±5 MPa. Refined grain structure (~2.54±1.11 μm), resulting from dynamic recrystallization, governed mechanical performance, while minor property variations were attributed to multi-stage thermal cycles |