Additive Friction Stir-Enabled Solid-State Additive Manufacturing for the Repair of 7075 Aluminum Alloy

The repair of high strength, high performance 7075 aluminum alloy is essential for a broad range of aerospace and defense applications. However, it is challenging to implement it using traditional fusion welding-based approaches, owing to hot cracking and void formation during solidification. Here,...

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Bibliographic Details
Published inApplied sciences Vol. 9; no. 17; p. 3486
Main Authors Griffiths, R. Joey, Petersen, Dylan T., Garcia, David, Yu, Hang Z.
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.09.2019
Subjects
Additive manufacturing
Aerospace industry
Alloys
Aluminum
Aluminum alloys
Corrosion
Critical components
Deposition
Experiments
Feasibility studies
Friction
friction stir
Friction stir welding
Fusion welding
Grooves
high-strength Al alloys
interface
Manufacturing industry
Microscopy
Military applications
Optimization
Process control
Repair
Residual stress
severe plastic deformation
Solid state
solid-state additive manufacturing
Solidification
Solids
Stress concentration
United States > US
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Summary:The repair of high strength, high performance 7075 aluminum alloy is essential for a broad range of aerospace and defense applications. However, it is challenging to implement it using traditional fusion welding-based approaches, owing to hot cracking and void formation during solidification. Here, the use of an emerging solid-state additive manufacturing technology, additive friction stir deposition, is explored for the repair of volume damages such as through -holes and grooves in 7075 aluminum alloy. Three repair experiments have been conducted: double through-hole filling, single through-hole filling, and long, wide-groove filling. In all experiments, additive friction stir deposition proves to be effective at filling the entire volume. Additionally, sufficient mixing between the deposited material and the side wall of the feature is always observed in the upper portions of the repair. Poor mixing and inadequate repair quality have been observed in deeper portions of the filling in some scenarios. Based on these observations, the advantages and disadvantages of using additive friction stir deposition for repairing volume damages are discussed. High quality and highly flexible repairs are expected with systematic optimization work on process control and repair strategy development in the future.
ISSN:2076-3417
2076-3417
DOI:10.3390/app9173486