Process-structure-property relations for as-deposited solid-state additively manufactured high-strength aluminum alloy

Solid-state additive manufacturing methods provide innovative solutions to circumvent problems associated with materials susceptible to hot cracking by avoiding liquid solid phase transformations. In this work, the process parameter influence on microstructural evolution and mechanical response of a fully dense aluminum alloy 7050 (AA7050) component manufactured via a rapid, solid-state additive manufacturing process known as Additive Friction Stir Deposition (AFS-D) was quantified for the first time. Three sections (starting dwell, transient, crossover of roads) of the deposition that exhibit differing thermomechanical processing histories were evaluated for the resulting microstructure and mechanical response. The microstructural characterization was performed on the as-deposited AA7050 via Electron Backscatter Diffraction (EBSD), Transmission electron microscopy (TEM), optical microscopy, and Scanning Electron Microscopy (SEM). The microstructural characterization revealed refined constituent particles and grains throughout the as-deposited AA7050 microstructure. Furthermore, quasi-static tensile experiments were conducted in both the build and transverse directions, in order to quantify the orientation influence on tensile properties of the as-deposited AA7050 build. Spatially dependent tensile properties were observed in the material due to heat input variation coarsening of secondary phases towards the initial layers of the AFS-D build. Post-mortem analysis revealed that voids nucleated and coalesced from the overgrowth of the strengthening precipitates present in the material, resulting in fracture.

Automated summary

Solid-state additive manufacturing methods were used to quantitatively assess the influence of process parameters on the microstructural evolution and mechanical response of an aluminum alloy 7050 component. The study highlighted the impact of thermomechanical histories during Additive Friction Stir Deposition (AFS-D) on microstructure, and observed spatially dependent tensile properties due to heat input variation. Post-mortem analysis revealed voids nucleated and coalesced from overgrowth of strengthening precipitates, leading to fracture in the material.