Abstract
Additive Manufacturing (AM) is crucial for Industry 4.0 where automation and real-time decision-making are to be performed with minimal human intervention. Most AM techniques involve melting metal powders layer-by-layer to build components which allows for complex geometries to be achieved; however, some challenges that inhibit it from becoming mainstream are hot cracking, porosity produced in the specimens, anisotropy and heterogeneity in the components with respect to the microstructure, mechanical properties, and crystallographic texture. Such problems could be overcome if AM is performed without melting. In this regard, additive friction stir deposition (AFSD) exhibits the highest potential for industrialization. AFSD involves depositing a solid metal feedstock bar layer-by-layer while being heated by a rotating tool. In this work, the process, microstructure, crystallographic texture, and hardness of Al 6082 alloy after AFSD have been investigated. A fine-grained microstructure was obtained. However, there was a reduction in the hardness by 54%. This could be due to the precipitate coarsening and dissolution during the processing.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Yu H Z, Jones M E, Brady G W, Griffiths R J, Garcia D, Rauch H A, Cox C D and Hardwick N (2018) Non-beam-based metal additive manufacturing enabled by additive friction stir deposition. Scr. Mater. 153: 122–30. https://doi.org/10.1016/j.scriptamat.2018.03.025
Yu, HZ (2022) Additive Friction Stir Deposition. Elsevier, Amsterdam.
Carroll B E, Palmer T A and Beese A M (2015) Anisotropic tensile behavior of Ti–6Al–4V components fabricated with directed energy deposition additive manufacturing. Acta Mater. 87: 309–20. https://doi.org/10.1016/j.actamat.2014.12.054
Sola A and Nouri A (2019) Microstructural porosity in additive manufacturing: The formation and detection of pores in metal parts fabricated by powder bed fusion. J. Adv. Manuf. Process. 1 (3): e10021. https://doi.org/10.1002/amp2.10021
Stopyra W, Gruber K, Smolina I, Kurzynowski T and Kuźnicka B (2020) Laser powder bed fusion of AA7075 alloy: Influence of process parameters on porosity and hot cracking. Addit. Manuf. 35: 101270. https://doi.org/10.1016/j.addma.2020.101270
Phillips B J, Avery D Z, Liu T, Rodriguez O L, Mason C J T, Jordon J B, Brewer L N and Allison P G (2019) Microstructure-deformation relationship of additive friction stir-deposition Al–Mg–Si. Mater. 7: 100387. https://doi.org/10.1016/j.mtla.2019.100387
Perry M E J, Griffiths R J, Garcia D, Sietins J M, Zhu Y and Yu H Z (2020) Morphological and microstructural investigation of the non-planar interface formed in solid-state metal additive manufacturing by additive friction stir deposition. Addit. Manuf. 35: 101293. https://doi.org/10.1016/j.addma.2020.101293
Joshi S S, Patil S M, Mazumder S, Sharma S, Riley D A, Dowden S, Banerjee R and Dahotre N B (2022) Additive friction stir deposition of AZ31B magnesium alloy. J.Magnes. Alloy. 10: 2404–20. https://doi.org/10.1016/j.jma.2022.03.011
Chang C I, Lee C J and Huang J C (2004) Relationship between grain size and Zener–Holloman parameter during friction stir processing in AZ31 Mg alloys. Scr. Mater. 51: 509–14. https://doi.org/10.1016/j.scriptamat.2004.05.043
Agrawal P, Haridas R S, Yadav S, Thapliyal S, Gaddam S, Verma R and Mishra R S (2021) Processing-structure-property correlation in additive friction stir deposited Ti-6Al-4V alloy from recycled metal chips. Addit. Manuf. 47: 102259. https://doi.org/10.1016/j.addma.2021.102259
Mrówka-Nowotnik G, Sieniawski J and Wierzbińska M (2007) Intermetallic phase particles in 6082 aluminium alloy. Arch. Mater. Sci. Eng. 28(2): 69–76
Phillips B J, Mason C J T, Beck S C, Avery D Z, Doherty K J, Allison P G and Jordon J B (2021) Effect of parallel deposition path and interface material flow on resulting microstructure and tensile behavior of Al-Mg-Si alloy fabricated by additive friction stir deposition. J. Mater. Process. Technol. 295: 117169. https://doi.org/10.1016/j.jmatprotec.2021.117169
Pariyar A, Perugu C S, Toth L S and Kailas S V (2021) Microstructure and mechanical behavior of polymer-derived in-situ ceramic reinforced lightweight aluminum matrix composite. J. Alloys Compd. 880: 160430. https://doi.org/10.1016/j.jallcom.2021.160430
Rui S-S, Han Q-N, Wang X, Li S, Ma X, Su Y, Cai Z, Du D and Shi H-J (2021) Correlations between two EBSD-based metrics Kernel Average Misorientation and Image Quality on indicating dislocations of near-failure low alloy steels induced by tensile and cyclic deformations. Mater. Today Commun. 27: 102445. https://doi.org/10.1016/j.mtcomm.2021.102445
Beyerlein I J and Tóth L S (2009) Texture evolution in equal-channel angular extrusion. Prog. Mater. Sci. 54: 427–510. https://doi.org/10.1016/j.pmatsci.2009.01.001
Acknowledgements
This work was supported by the UKRI Future Leaders Fellowship, MR/T019123/2. The authors thank Mohammed Bhaiyat from AMRC, North West for his help in conducting the AFSD experiments.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Minerals, Metals & Materials Society
About this paper
Cite this paper
Pariyar, A., Yasa, E., Sharman, A., Guan, D. (2024). Investigations on the Solid-State Additive Manufacturing of Al Alloy: Process, Microstructure, and Crystallographic Texture. In: Wagstaff, S. (eds) Light Metals 2024. TMS 2024. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-031-50308-5_37
Download citation
DOI: https://doi.org/10.1007/978-3-031-50308-5_37
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-50307-8
Online ISBN: 978-3-031-50308-5
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)