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Dynamic Behavior Characterization of Aluminum Alloy 7020 Manufactured Using the Additive Friction Stir Deposition Process

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Abstract

In this research, we study the feasibility of using the solid-state additive manufacturing process, additive friction stir deposition (AFSD), as a suitable technology for creating bulk structural components using aluminum alloy 7020. Using a set of the acceptable processing conditions, a fully dense 92-mm-tall build was successful created. Microstructural characterization of the as-deposited AA7020 revealed a highly refined and equiaxed grain structure compared to the AA7020-T651 feedstock material. Tensile specimens were extracted from the as-deposited component in longitudinal direction to evaluate strain-rate dependance and fatigue behavior. In the quasi-static regime (0.001 s−1), the as-deposited AA7020 exhibited layer dependence throughout the build direction indicated by a diminished YS and UTS when comparing the final, intermediate, and initial layers of the deposit and the feedstock material. The layer dependence noted in the quasi-static regime is attributed to the increasing thermal input in the build direction during AFSD process. However, in the high-rate regime (2000 s−1), the as-deposited material had a similar flow stress to the feedstock material. Additionally, stress-life experiments determined a decrease in fatigue life between the final, intermediate, and initial layers of the deposit due to the inconsistent MgZn-rich particle coarsening inherent to the AFSD process.

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Acknowledgements

The authors thank the Point of Need Innovations (PONI) at Baylor University, the UA Manufacturing at the Point-of-Need Center (MPNC), and the Alabama Analytical Research Center (AARC) for their support of this project. Additionally, the authors thank US Army Combat Capabilities Development Command (DEVCOM) Ground Vehicle System Command (GVSC) for the financial support of this project. DISTRIBUTION A. Approved for public release; distribution unlimited. OPSEC7288.

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Authors and Affiliations

  1. Point-of-Need Innovations (PONI) Center, Baylor University, Waco, TX, 76704, USA

    M. B. Williams, L. P. Cahalan, J. B. Jordon & P. G. Allison

  2. Department of Metallurgical Engineering, The University of Alabama, Tuscaloosa, AL, 35487, USA

    J. J. Lopez, L. I. Perez-Andrade & L. N. Brewer

  3. Standard Mechanics, LLC, Starkville, MS, 39795, USA

    R. T. Leonard III

  4. U.S. Army DEVCOM Ground Vehicles System Center (GVSC), Warren, MI, 48092, USA

    M. M. McDonnell, M. R. Kelly & A. D. Lalonde

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  1. M. B. Williams
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  2. L. P. Cahalan
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Williams, M.B., Cahalan, L.P., Lopez, J.J. et al. Dynamic Behavior Characterization of Aluminum Alloy 7020 Manufactured Using the Additive Friction Stir Deposition Process. JOM 75, 4868–4880 (2023). https://doi.org/10.1007/s11837-023-06126-5

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