Yakubov, V., Ostergaard, H., Bhagavath, S. et al. (7 more authors) (2024) Multimodal defect analysis and application of virtual machining for solid-state manufactured aluminium structure. Progress in Additive Manufacturing. ISSN 2363-9512
Abstract
Additive friction stir deposition (AFSD) is an emerging solid-state non-fusion additive manufacturing (AM) technology, which produces parts with wrought-like material properties, high deposition rates, and low residual stresses. However, impact of process interruption on defect formation and mechanical properties has not yet been well addressed in the literature. In this study, Al6061 aluminium structure with two final heights and deposition interruption is successfully manufactured via AFSD and characterised. Defect analysis conducted via optical microscopy, electron microscopy, and X-ray computed tomography reveals > 99% relative density with minimal defects in centre of the parts. However, tunnel defects at interface between substrate and deposit as well as kissing bonds are present. Edge of deposit contains tunnel defects due to preference for greater material deposition on advancing side of rotating tool. Virtual machining highlights the ability to remove defects via post-processing, avoiding mechanical performance impact of stress concentrating pores. Electron backscatter diffraction revealed regions with localised shear bands that contain 1–5 µm equivalent circular diameter grains. Kissing bonds are exhibited in areas separated by large grain size difference. Meanwhile, Vickers hardness testing reveals hardness variation with deposit height. This work advances the understanding of complex microstructure development, material flow, and mechanical behaviour of AFSD Al6061 alloy.
Metadata
Item Type: | Article |
---|---|
Authors/Creators: |
|
Copyright, Publisher and Additional Information: | © Crown 2024. This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/. |
Keywords: | Additive friction stir deposition; Solid-state additive manufacturing; Defects; Microstructure; Hardness |
Dates: |
|
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) |
Funding Information: | Funder Grant number Engineering and Physical Sciences Research Council EP/P006566/1 Engineering and Physical Sciences Research Council EP/W003333/1 |
Depositing User: | Symplectic Sheffield |
Date Deposited: | 16 Jan 2025 15:13 |
Last Modified: | 16 Jan 2025 15:13 |
Status: | Published online |
Publisher: | Springer Science and Business Media LLC |
Refereed: | Yes |
Identification Number: | 10.1007/s40964-024-00904-6 |
Related URLs: | |
Open Archives Initiative ID (OAI ID): | oai:eprints.whiterose.ac.uk:221484 |