Yakubov, V. orcid.org/0000-0003-3893-0089, Ostergaard, H., Hughes, J. orcid.org/0000-0002-5380-6345 et al. (4 more authors) (2024) Evolution of material properties and residual stress with increasing number of passes in aluminium structure printed via additive friction stir deposition. Materials, 17 (14). 3457. ISSN 1996-1944
Abstract
Additive friction stir deposition (AFSD) is an emerging solid-state additive manufacturing process with a high deposition rate. Being a non-fusion additive manufacturing (AM) process, it significantly eliminates problems related to melting such as cracking or high residual stresses. Therefore, it is possible to process reactive materials or high-strength alloys with high susceptibility to cracking. Although the residual stresses are lower in this process than with the other AM processes, depending on the deposition path, geometry, and boundary conditions, residual stresses may lead to undesired deformations and deteriorate the dimensional accuracy. Thermal cycling during layer deposition, which also depends on the geometry of the manufactured component, is expected to affect mechanical properties. To this day, the influence of the deposit geometry on the residual stresses and mechanical properties is not well understood, which presents a barrier for industry uptake of this process for large-scale part manufacturing. In this study, a stepped structure with 4, 7, and 10 passes manufactured via AFSD is used to investigate changes in microstructure, residual stress, and mechanical property as a function of the number of passes. The microstructure and defects are assessed using scanning electron microscopy and electron backscatter diffraction. Hardness maps for each step are created. The residual stress distributions at the centreline of each step are acquired via non-destructive neutron diffraction. The valuable insights presented here are essential for the successful utilisation of AFSD in industrial applications.
Metadata
Item Type: | Article |
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Authors/Creators: |
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Copyright, Publisher and Additional Information: | © 2024 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). |
Keywords: | additive friction stir deposition; additive manufacturing; aluminium alloy; hardness; microstructure; residual stress |
Dates: |
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Institution: | The University of Sheffield |
Academic Units: | The University of Sheffield > University of Sheffield Research Centres and Institutes > AMRC with Boeing (Sheffield) The University of Sheffield > Advanced Manufacturing Institute (Sheffield) > AMRC with Boeing (Sheffield) |
Depositing User: | Symplectic Sheffield |
Date Deposited: | 12 Aug 2024 14:23 |
Last Modified: | 12 Aug 2024 14:23 |
Status: | Published |
Publisher: | MDPI AG |
Refereed: | Yes |
Identification Number: | 10.3390/ma17143457 |
Related URLs: | |
Open Archives Initiative ID (OAI ID): | oai:eprints.whiterose.ac.uk:215972 |