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Printing functional metallic 3D parts using a hybrid friction-surfacing additive manufacturing process

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Abstract

This paper presents a hybrid additive manufacturing (AM) process combining multilayer friction surfacing (FS) and metal machining operations. While friction surfacing has been known as a part repair or coating process, we here present an attempt to use it to build whole 3D metallic parts. The feasibility of the process is tested using heat-treatable Aluminum alloy AA6061 rod on a mild steel substrate. A series of FS experiments was conducted with the purpose to identify suitable process settings. This included different combinations of rotational and travel speeds of the FS rod. Quality of deposited layers was assessed using different indicators including bond width, layer uniformity, layer thickness, and others. ANOVA was conducted to reveal the effects of process parameter settings on the quality metrics. Two metallic parts were printed successfully, which demonstrates the feasibility of the proposed hybrid process.

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Funding

This research was funded by Deanship of Research at Jordan University of Science and Technology, Grant No.20190036.

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Authors and Affiliations

  1. Industrial Engineering Department, Jordan University of Science and Technology, P.O.Box 3030, Irbid, 22110, Jordan

    Esraa S. Abdelall, Abdullah F. Al-Dwairi & Shatha Mahmoud Al-Raba’a

  2. Department of Industrial and Manufacturing System Engineering, 3004 Black Engineering, 2529 Union Drive, Ames, IA, 50011, USA

    Mohamed Eldakroury

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  1. Esraa S. Abdelall
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  2. Abdullah F. Al-Dwairi
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Correspondence to Esraa S. Abdelall.

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The original online version of this article was revised: figure 10 was not correct.

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Abdelall, E.S., Al-Dwairi, A.F., Al-Raba’a, S.M. et al. Printing functional metallic 3D parts using a hybrid friction-surfacing additive manufacturing process. Prog Addit Manuf 6, 731–741 (2021). https://doi.org/10.1007/s40964-021-00193-3

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