Microstructural and Mechanical Characterization of Additive Friction Stir-Deposition of Aluminum Alloy 5083 Effect of Lubrication on Material Anisotropy

Additive Friction Stir-Deposition (AFS-D) is a transformative, metallic additive manufacturing (AM) process capable of producing near-net shape components with a wide variety of material systems. The solid-state nature of the process permits many of these materials to be successfully deposited without the deleterious phase and thermally activated defects commonly observed in other metallic AM technologies. This work is the first to investigate the as-deposited microstructure and mechanical performance of a free-standing AA5083 deposition. An initial process parameterization was conducted to down-select optimal parameters for a large deposition to examine build direction properties. Microscopy revealed that constitutive particles were dispersed evenly throughout the matrix when compared to the rolled feedstock. Electron backscatter diffraction revealed a significant grain refinement from the inherent dynamic recrystallization from the AFS-D process. Tensile experiments determined a drop in yield strength, but an improvement in tensile strength in the longitudinal direction. However, a substantial reduction in tensile strength was observed in the build direction of the structure. Subsequent fractographic analysis revealed that the recommended lubrication applied to the feedstock rods, necessary for successful depositions via AFS-D, was ineffectively dispersed into the structure. As a result, lubrication contamination became entrapped at layer boundaries, preventing adequate bonding between layers.

Automated summary

AFS-D is a transformative metallic AM process capable of producing near-net shape components with a wide variety of material systems. The solid-state nature of the process allows for successful deposition of materials without common defects seen in other metallic AM technologies. The study found significant grain refinement and impact on material properties from the AFS-D process, and noted that recommended lubrication for feedstock rods may not be effectively dispersed into the structure, affecting bonding between layers.