Effect of Additive Friction Stir Deposition Processing on the Microstructure and Mechanical Properties of 1045 Steel

Using additive friction stir deposition (AFSD), the poor weldability of 1045 steel can be solved, facilitating the efficient and high-performance additive manufacturing of its components. This study selected spherical 1045 steel powder and investigated key factors influencing mechanical properties, including deposition temperature, tool rotational rate, and axial force. The results showed that dynamic recrystallization (DRX) occurred in AFSD 1045 steel, which produced randomly oriented fine equiaxed grains with a size range of 1-3 µm and was sensitive to changes in tool rotational rate and axial force. The AFSD 1045 steel, with a maximum surface hardness of 477.2 HV, ultimate tensile strength of 1061.9-1172.3 MPa, and elongation of 8.6-19.0%, has superior overall mechanical properties compared with other forming processes. Moreover, by analyzing tensile fracture morphology, geometrically necessary dislocation (GND) density, and coincidence site lattice (CSL) boundary distribution characteristics, the strengthening mechanism in AFSD 1045 steel was discussed. The research findings serve as a reference for optimizing the AFSD process for 1045 steel and supply a new alternative for joining and manufacturing this material.