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Towards Understanding the Relationships between Processing Conditions and Mechanical Performance of the Additive Friction Stir Deposition Process

Authors :
Malcolm B. Williams
Ning Zhu
Nick I. Palya
Jacob B. Hoarston
Martin M. McDonnell
Matthew R. Kelly
Aaron D. Lalonde
Luke N. Brewer
James B. Jordon
Paul G. Allison
Source :
Metals, Vol 13, Iss 10, p 1663 (2023)
Publication Year :
2023
Publisher :
MDPI AG, 2023.

Abstract

In this research, we explore the preliminary effects of processing conditions using a novel additive manufacturing (AM) process, known as additive friction stir deposition (AFSD), on resulting build direction (BD) mechanical performance. Using the AFSD process, a feasibility study of three AM builds of identical size are created using differentiating processing parameters. A relationship referred to as the deposition pitch, exhibiting similarities to weld pitch, is determined to be a simple but effective predictor of the interlayer bonding in AFSD processing of AA7020. The deposition pitch directly correlates the necessary temperature, time, and pressure required for effective solid-state bonding. Using this correlation, increased mechanical performance in the BD is achieved through an increase in deposition pitch. A reduction in the deposition pitch from 4.46 rev/mm to 1.08 rev/mm resulted in a significant decrease in failure strain from 24.4% to 0.82%, with the failure mechanism shifting from a ductile failure to brittle failure. The inverse relationship between grain refinement and BD failure strain at high deposition pitches suggests deposition pitch and heat input are the dominant factors in the resulting BD mechanical properties.

Details

Language :
English
ISSN :
20754701
Volume :
13
Issue :
10
Database :
Directory of Open Access Journals
Journal :
Metals
Publication Type :
Academic Journal
Accession number :
edsdoj.05d1e27d20474797a890ec34dcabd3a5
Document Type :
article
Full Text :
https://doi.org/10.3390/met13101663