Search for: All records

Solid-state additive friction stir deposition (AFSD) is a thermomechanical-based additive manufacturing technique. For this study, AFSD was utilized to produce aluminum alloy 6061 (AA6061) blocks with varying layer thicknesses (1 mm, 2 mm, and 3 mm). The mechanical properties were assessed through uniaxial tensile tests and Vickers microhardness measurement, and statistical analysis was employed to investigate differences among data groups. The results revealed that the deposition layer thickness influences tensile properties in the building (Z) direction, while the properties in the X and Y directions showed minor differences across the three AFSD blocks. Furthermore, variations in tensile properties were observed depending on the sample orientation in the AFSD blocks and its depth-wise position in the part in the building direction. The microhardness values decreased non-linearly along the building direction, spread across the width of the part’s cross-section, and highlighted that the deposition layer thickness significantly affects this property. The 1 mm block exhibited lower average microhardness values than the 2 mm and 3 mm blocks. The temperature histories and dynamic heat treatment are influenced by the deposition layer thickness and depend on the location of the point being studied in the part, resulting in variations in the microstructure and mechanical properties along the building direction and across the part’s width. 

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.