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Generating Lap Joints Via Friction Stir Spot Welding on DP780 Steel

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Additively Manufactured Parts from AA2011-T6 Large-Diameter Feedstocks Using Friction Stir Deposition.

Naser A Alsaleh¹, Mohamed M El-Sayed Seleman², Ahmed M M Hassan³

¹Department of Mechanical Engineering, College of Engineering, Imam Mohammad Ibn Saud Islamic University, Riyadh 11432, Saudi Arabia.

Materials (Basel, Switzerland)

|July 29, 2023

Summary

This study demonstrates successful additive friction stir deposition of AA2011-T6 aluminum alloy using large diameter rods. Optimized parameters significantly enhance material properties, achieving refined grain structures and increased strength.

Keywords:

AA2011-T6 aluminum alloy additive friction stir deposition feed rate mechanical properties microstructure solid-state additive manufacturing spindle rotation speed

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Area of Science:

Materials Science
Manufacturing Engineering
Metallurgy

Background:

Additive manufacturing of high-strength aluminum alloys presents challenges, particularly with large diameter feedstocks.
Additive Friction Stir Deposition (A-FSD) is explored for solid-state fabrication of AA2011-T6.
Optimizing process parameters is crucial for successful deposition and material property enhancement.

Purpose of the Study:

To investigate the feasibility of fabricating AA2011-T6 products using A-FSD with 40 mm diameter rods.
To determine the optimal A-FSD parameters (spindle speed and feed rate) for producing sound parts.
To characterize the microstructural and mechanical property changes in the deposited AA2011-T6.

Main Methods:

Utilized additive friction stir deposition (A-FSD) with AA2011-T6 rods (40 mm diameter).
Varied spindle rotation speeds (400-1200 rpm) and feed rates (1, 3, 5 mm/min).
Evaluated visual appearance, macrostructure, microstructure (optical microscopy, SEM/EDS), hardness, and compressive strength.

Main Results:

Successfully fabricated sound AA2011-T6 parts using A-FSD at 600-800 rpm and feed rates of 1-5 mm/min.
Spindle speed and feed rate critically influence FSDP quality and axial load.
Deposited materials exhibited refined grain structures (up to 81.31% reduction) and improved hardness (up to 85%) and compressive strength (up to 93%) compared to base material.

Conclusions:

Additive friction stir deposition is a viable technique for fabricating AA2011-T6 components from large diameter feedstocks.
Optimized A-FSD parameters significantly refine microstructure and enhance mechanical properties.
The study provides valuable insights into controlling A-FSD process variables for high-strength aluminum alloys.