About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
|
| Symposium
|
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
|
| Presentation Title |
Development of Wire-Fed Friction Stir Additive Manufacturing of AA 4043 on AA 6061 Using Conventional Knee Mill |
| Author(s) |
Laura Catalano, Cordelia Margaret Norris, Alannah Ross, Jonathan Dean, Elizabeth Mamros, John Roth |
| On-Site Speaker (Planned) |
Cordelia Margaret Norris |
| Abstract Scope |
Wire friction stir additive manufacturing (W-FSAM) is emerging as a useful alternative to bar-fed
methods of FSAM due to its continuous feeding. Proposed is a straight shaft method of continuous
wire-fed FSAM, denoted as the auger method, implementable on retrofitted conventional mills,
enabling easy adaptability in machine shops of all scales. This work investigates the use of readily
available wire and substrate materials to showcase how the wire-fed FSAM method can be
executed utilizing accessible materials for additive builds. Experiments were conducted by
manually operating a Bridgeport knee mill to deposit 1.2 mm diameter aluminum alloy (AA) 4043
wire onto an AA 6061 substrate. Additively manufactured build samples were analyzed using
scanning electron microscopy, microhardness testing, micro-computed tomography, and confocal
microscopy to confirm that the AM material properties were comparable to the as-received wire
material. Resulting properties (e.g., porosity) were also comparable to other metal forming
processes and FSAM methods. |
| Proceedings Inclusion? |
Undecided |