TY - JOUR

T1 - Application of friction surfacing for solid state additive manufacturing of cylindrical shell structures

AU - Kallien, Zina

AU - Rath, Lars

AU - Roos, Arne

AU - Klusemann, Benjamin

N1 - Funding Information: This project has received funding from the European Research Council (ERC) under the European Unions Horizon 2020 research and innovation programme (grant agreement No 101001567 ). Publisher Copyright: © 2023 The Author(s)

PY - 2024/2/1

Y1 - 2024/2/1

N2 - Solid-state additive manufacturing (AM) via friction stir based processes is gaining increased attention as these techniques are feasible for several similar and dissimilar material combinations and induce significantly lower energy input to the subjacent structure than fusion-based approaches as material melting is avoided. Available research concentrates on linear depositions; however, further development of these techniques towards application necessitates more complex deposition paths, e.g. curves and the crossing of edges of previously deposited layers. In this study, the solid-state layer deposition process of friction surfacing (FS) is investigated in terms of process behavior and appearance of the resulting deposit when curved deposition paths are applied. With advancing side on the curve's inner edge, material build-up occurs predominantly on this side of the layer, which results in a deposit of inhomogeneous thickness. This phenomenon is related to the FS process characteristic due to the superposition of rotational and travel movement on a curvature, and is more pronounced for curves with small radii. A further challenge exists for closed structures, where the deposition has to cross previously deposited layers. This can be successfully achieved by reducing the travel speed prior to passing the edge to provide sufficient plasticized material thickness below the stud tip. Overall, the study provides an understanding of the FS process behavior and process parameters for curved paths. Furthermore, recommendations for process control and path planning, e.g. for building closed cylindrical shell structures, are deduced.

AB - Solid-state additive manufacturing (AM) via friction stir based processes is gaining increased attention as these techniques are feasible for several similar and dissimilar material combinations and induce significantly lower energy input to the subjacent structure than fusion-based approaches as material melting is avoided. Available research concentrates on linear depositions; however, further development of these techniques towards application necessitates more complex deposition paths, e.g. curves and the crossing of edges of previously deposited layers. In this study, the solid-state layer deposition process of friction surfacing (FS) is investigated in terms of process behavior and appearance of the resulting deposit when curved deposition paths are applied. With advancing side on the curve's inner edge, material build-up occurs predominantly on this side of the layer, which results in a deposit of inhomogeneous thickness. This phenomenon is related to the FS process characteristic due to the superposition of rotational and travel movement on a curvature, and is more pronounced for curves with small radii. A further challenge exists for closed structures, where the deposition has to cross previously deposited layers. This can be successfully achieved by reducing the travel speed prior to passing the edge to provide sufficient plasticized material thickness below the stud tip. Overall, the study provides an understanding of the FS process behavior and process parameters for curved paths. Furthermore, recommendations for process control and path planning, e.g. for building closed cylindrical shell structures, are deduced.

KW - Additive manufacturing

KW - Aluminum

KW - Multi-layer friction surfacing

KW - Solid state layer deposition

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=85178130807&partnerID=8YFLogxK

U2 - 10.1016/j.addlet.2023.100184

DO - 10.1016/j.addlet.2023.100184

M3 - Journal articles

AN - SCOPUS:85178130807

VL - 8

JO - Additive Manufacturing Letters

JF - Additive Manufacturing Letters

SN - 2772-3690

M1 - 100184

ER -