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Effect of rotational speed and feed rate on microstructure and mechanical properties of 6061 aluminum alloy manufactured by additive friction stir deposition

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Abstract

Additive friction stir deposition (AFSD) is attractive for its ability to create freeform and fully dense structures without melting and solidification. Hence, additive friction stir deposition is an alternative to fusion-based additive manufacturing technology. In this study, the influence of the AFSD parameter (i.e., rotational speed and feed rate) on the mechanical properties and microstructure of 6061 aluminum alloy is investigated. The as-deposited 6061 aluminum alloy exhibits a relatively homogeneous microstructure with extensive equiaxed grains. Compared to the feedstock material, the ultimate tensile strength of the as-deposited 6061 aluminum alloy decreased to 65% from 320 to 210 MPa. The results of electron backscatter diffraction indicate that continuous dynamic recrystallization occurs during the AFSD process. Furthermore, it is evidence that the grain size and ultimate tensile strength are positively correlated with feed rate and rotational speed, whereas the elongation at break decreases with the increase in feed rate and rotational speed.

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Acknowledgements

The authors would like to acknowledge Aerospace Engineering Equipment (Suzhou) Co., Ltd. (Suzhou, China) for their support of this work.

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Authors and Affiliations

  1. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, 210094, People’s Republic of China

    Gang Chen, Kai Wu & Yu Wang

  2. Aerospace Engineering Equipment (Suzhou) Co. Ltd., Suzhou, 215200, People’s Republic of China

    Zhixiong Zhu, Pan Nie & Fengfeng Hu

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  1. Gang Chen
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  2. Kai Wu
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Correspondence to Kai Wu.

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Chen, G., Wu, K., Wang, Y. et al. Effect of rotational speed and feed rate on microstructure and mechanical properties of 6061 aluminum alloy manufactured by additive friction stir deposition. Int J Adv Manuf Technol 127, 1165–1176 (2023). https://doi.org/10.1007/s00170-023-11527-6

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