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Abstract Additive friction stir deposition (AFSD) is a novel additive manufacturing technique that enables the fabrication of components in the solid state. Given the benefits of AFSD, understanding the behavior of various feedstock materials after undergoing the AFSD process is crucial for optimizing their performance in structural applications. This study aims to evaluate the effects of AFSD on an Al–Mg alloy, Al5086, comparing it to its initial H32 condition to assess the changes in mechanical properties, microstructure, corrosion resistance, microhardness, and electrical conductivity. Tensile testing showed a 23% reduction in yield strength for as-deposited samples, while ultimate tensile strength remained comparable to the feedstock. Ductility improved significantly, with elongation to failure increasing by 77%, attributed to grain refinement and dynamic recovery. Microhardness decreased by 16% in lower layers due to thermal exposure, but electrical conductivity remained stable, indicating minimal solute atom redistribution. The Nitric Acid Mass Loss Test (NAMLT) revealed a 245% increase in corrosion rate for the AFSD material, linked to the higher density of grain boundaries acting as pathways for corrosion. These findings highlight AFSD’s potential for improving ductility and formability. However, they underscore the need for optimization to reduce corrosion susceptibility and address mechanical strength trade-offs. Future work should focus on fine-tuning process parameters or implementing post-treatment methods to enhance corrosion and mechanical performance. 

The solid-state additive friction stir deposition (AFSD) process is a layer-by-layer metal 3D-printing technology. In this study, AFSD is used to fabricate Al–Cu–Li 2050 alloy parts. The hardness values for various regions of the as-deposited built parts are measured, and the results are contrasted with those of the feedstock material. The as-fabricated Al2050 parts are found to have a unique hardness distribution due to the location-specific variations in the processing temperature profile. The XRD results indicate the presence of the secondary phases in the deposited parts, and EDS mapping confirms the formation of detectable alloying particles in the as-deposited Al2050 matrix. The AFSD thermal–mechanical process causes the unique hardness distribution and the reduced microhardness level in the AFSD components, in contrast to those of the feedstock material.