Exploring temperature-controlled friction stir powder additive manufacturing process for multi-layer deposition of aluminum alloys
2022 (English)In: Journal of Materials Research and Technology, ISSN 2238-7854, E-ISSN 2214-0697, Vol. 20, p. 260-268Article in journal (Refereed) Published
Abstract [en]
This paper presents preliminary study on multi-layer deposition of aerospace grade Al 6061 alloy by novel friction stir powder additive manufacturing process. Minimum temperature of deposition was in-situ maintained using close loop temperature-controlled system for minimizing thermal gradient in the build direction. Maximum temperature during the deposition was monitored in-situ using pyrometer and thermal imaging camera. Use of a tool with circumferential and radial grooves and continuous external heating facilitated smooth three-layer deposition of Al 6061 alloy with 60% deposition efficiency and 417 degrees C as maximum deposition temperature. Larger value of temperature at deposition zone improved material flowability and deposition quality. Microstructure of multi-layer deposition found to consist of fine sub-grains. Element analysis showed uniform distribution of major alloying elements in it. Phase analysis revealed Al along with Mg2Si hardening precipitates. Tensile strength and microhardness were close to the commercially available wrought AA6061-T4 alloy. It showed ductility with 16% elongation. The presented process is a viable alternative to fusion-based additive manufacturing processes for multi-layer depositions of aerospace grade and other lightweight alloys which are difficult-to-additively-manufacture.
Place, publisher, year, edition, pages
Elsevier, 2022. Vol. 20, p. 260-268
Keywords [en]
Friction stir; Additive manufacturing; Aerospace grade Al alloys; Close loop; Temperature-controlled
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-19304DOI: 10.1016/j.jmrt.2022.07.049ISI: 000856726500006Scopus ID: 2-s2.0-85139455214OAI: oai:DiVA.org:hv-19304DiVA, id: diva2:1720896
Note
The authors acknowledge Additive and Micromanufacturing Lab (AMAL), Advance Welding Lab (AWL), and other labs of IIT Indore for providing research facilities for the present work. Authors acknowledge Science and Engineering Research Board (SERB), Govt. of India, for their financial assistance through Project File No. SRG/2019/002353. The first author wishes to thank Department of Science and Technology (DST), Govt. of India, for funding him as DST-INSPIRE Research Fellow (IF190359) to pursue this research work.
This is an open access article under the CCBY license (http://creativecommons.org/licenses/by/4.0/).
2022-12-202022-12-202024-09-02