Towards High-Rate Additive Friction Stir Deposition of Al 7075: Tribological, Microstructural, and Mechanical Properties

IF 4.5 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Metals and Materials International Pub Date : 2026-07-10 DOI:10.1007/s12540-025-02195-0

Ehsan Bagheri, Lijesh Koottaparambil, Noushin Adibi, Huan Ding, Saeid Zavari, Michael Khonsari, Shengmin Guo

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引用次数: 0

Abstract

Increasing the deposition rate in additive manufacturing (AM) techniques is critical to enhance production efficiency and reduce costs. In this context, additive friction stir deposition (AFSD) offers great potential for high-rate fabrication of metallic parts. It is essential to further develop this technique to expand the range of processable materials at high deposition rates. In this study, Al 7075-T651 parts were deposited by AFSD at a rate approximately 2.6 times higher than those reported in previous studies. The AFSD output parameters and the deposited part’s properties including mechanical properties and microstructure were evaluated and compared with literature. The results indicated increases in average force and torque by 70.9% and 36.7% respectively during the high-rate AFSD deposition process, along with 12% and 22.4% improvements in the average hardness and tensile strength, respectively for the AFSD part. The property changes were attributed to the reduced heat input during the process, finer grain microstructure, and a higher density of dislocations. Additionally, tribological properties of the high-rate as-deposited Al 7075 part were assessed and compared to the feedstock material. The results revealed improved wear resistance in the deposited part, particularly in the bottom layers, in most cases, which was primarily attributed to their higher toughness.

Graphical Abstract

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高速率添加剂搅拌摩擦沉积Al 7075：摩擦学、显微组织和力学性能

提高增材制造（AM）技术的沉积速率对于提高生产效率和降低成本至关重要。在这种情况下，添加剂搅拌摩擦沉积（AFSD）为高速制造金属零件提供了巨大的潜力。进一步发展该技术以扩大高沉积速率下可加工材料的范围是至关重要的。在本研究中，Al 7075-T651零件的AFSD沉积速率大约是以往研究报道的2.6倍。评估了AFSD输出参数和沉积件的力学性能和微观结构，并与文献进行了比较。结果表明，在高速AFSD沉积过程中，AFSD零件的平均力和扭矩分别提高了70.9%和36.7%，平均硬度和抗拉强度分别提高了12%和22.4%。性能的变化是由于加工过程中热量输入减少，晶粒组织更细，位错密度更高。此外，对高速率沉积Al 7075零件的摩擦学性能进行了评估，并与原料材料进行了比较。结果表明，在大多数情况下，沉积部件的耐磨性有所提高，特别是底层，这主要归因于它们的高韧性。图形抽象

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Metals and Materials International 工程技术-材料科学：综合

CiteScore

7.10

自引率

8.60%

发文量

197

审稿时长

3.7 months

期刊介绍： Metals and Materials International publishes original papers and occasional critical reviews on all aspects of research and technology in materials engineering: physical metallurgy, materials science, and processing of metals and other materials. Emphasis is placed on those aspects of the science of materials that are concerned with the relationships among the processing, structure and properties (mechanical, chemical, electrical, electrochemical, magnetic and optical) of materials. Aspects of processing include the melting, casting, and fabrication with the thermodynamics, kinetics and modeling.