TY - JOUR

T1 - Additive friction stir deposition vs. friction surfacing

T2 - Comparison of friction stir-based approaches for groove repair of high strength aluminum alloys

AU - Kallien, Zina

AU - Rojas, Victor A.

AU - Aspes, Pietro

AU - Swinney, Adam N.

AU - Fleck, Trevor J.

AU - Jordon, J. Brian

AU - Allison, Paul G.

AU - Klusemann, Benjamin

N1 - Publisher Copyright: © 2025 The Authors

PY - 2025/10

Y1 - 2025/10

N2 - Friction stir-based solid-state layer deposition techniques show considerable potential as additive manufacturing approach but also for repair applications. Researchers investigate different techniques, where the layer deposition is mainly based on friction and plastic deformation of a consumable material. The approaches differ in terms of setup and if they utilize a tool to feed the consumable material. This study presents a direct comparison of different friction-based solid-state layer deposition techniques, i.e., additive friction stir deposition (AFSD) and friction surfacing (FS), for the groove repair on the example of high strength aluminum alloys. All deposition strategies present a robust process behavior for groove repair. The AFSD deposits present a sound metallurgical bonding, whereas the FS repair presents some unbonded regions; however, this is significantly improved when hybrid friction diffusion bonding (HFDB) is applied as post-processing technique to the FS deposit. A homogeneous average grain size is obtained in the AFSD deposits, whereas FS deposits present slight variations along layer thickness. The hardness distribution shows that the heat input is higher for AFSD, indicated by larger heat-affected zones in the substrate and lower hardness in the deposited material compared to FS. Overall, both approaches can achieve a successful groove repair with process-characteristic differences.

AB - Friction stir-based solid-state layer deposition techniques show considerable potential as additive manufacturing approach but also for repair applications. Researchers investigate different techniques, where the layer deposition is mainly based on friction and plastic deformation of a consumable material. The approaches differ in terms of setup and if they utilize a tool to feed the consumable material. This study presents a direct comparison of different friction-based solid-state layer deposition techniques, i.e., additive friction stir deposition (AFSD) and friction surfacing (FS), for the groove repair on the example of high strength aluminum alloys. All deposition strategies present a robust process behavior for groove repair. The AFSD deposits present a sound metallurgical bonding, whereas the FS repair presents some unbonded regions; however, this is significantly improved when hybrid friction diffusion bonding (HFDB) is applied as post-processing technique to the FS deposit. A homogeneous average grain size is obtained in the AFSD deposits, whereas FS deposits present slight variations along layer thickness. The hardness distribution shows that the heat input is higher for AFSD, indicated by larger heat-affected zones in the substrate and lower hardness in the deposited material compared to FS. Overall, both approaches can achieve a successful groove repair with process-characteristic differences.

KW - Additive friction stir deposition

KW - Aluminum

KW - Defect analysis

KW - Friction surfacing

KW - Groove repair

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=105013123418&partnerID=8YFLogxK

U2 - 10.1016/j.matdes.2025.114511

DO - 10.1016/j.matdes.2025.114511

M3 - Journal articles

AN - SCOPUS:105013123418

VL - 258

JO - Materials and Design

JF - Materials and Design

SN - 0264-1275

M1 - 114511

ER -