Fundamental study of multi-track friction surfacing deposits for dissimilar aluminum alloys with application to additive manufacturing

Publikation: Beiträge in ZeitschriftenZeitschriftenaufsätzeForschungbegutachtet


Friction surfacing is an emerging solid-state coating technology based on frictional heat induced plastic deformation at the tip of a consumable metallic stud that allows to deposit layers with a fine-grained recrystallized microstructure at temperatures below the melting point. The generation of sound, defect-free metallurgical joints between multiple adjacent overlapping friction surfacing deposits, also referred to as multi-track friction surfacing, from dissimilar aluminum alloys is the focus of this experimental work. An extensive volumetric defect analysis is carried out for various overlap configurations, including post-processing strategies in order to assess the inter-track bonding integrity using microscopic characterization techniques and micro-computed tomography. The effect of layer arrangement and overlap distance on the volumetric defect formation in both inter-track and layer-to-substrate interface is quantified and discussed. Post-processing via hybrid friction diffusion bonding process demonstrates a significant reduction in defect volume ratio, proving higher material efficiency. The gained knowledge was used to successfully build a multi-track multi-layer friction surfacing stack, demonstrating the suitability of this process for large-scale additive manufacturing components. The subsequent mechanical analysis reveals excellent homogeneous isotropic tensile properties of the additive structure in the range of the base material tensile strength.
ZeitschriftMaterials and Design
Anzahl der Seiten15
PublikationsstatusErschienen - 01.07.2022

Bibliographische Notiz

Funding Information:
The authors would like to thank Mr. H. Tek from Helmholtz-Zentrum Hereon, Institute of Materials Mechanics-Laser Processing and Structural Assessment, for the support in conducting the tensile testing experiments. In addition, the authors want to thank Dr. Vasyl Mikhailovich Haramus of the Helmholtz-Zentrum Hereon, Institute of Metallic Biomaterials, for facilitating the micro-computed tomographic image acquisition. The authors would like to acknowledge the opportunity for microCT scans at the Manchester Imaging Branchline (I13-2), at Diamond Light Source UK.

Funding Information:
B.K. acknowledges funding from the European Research Council (ERC) under the European Union’s Horizon 2020 research and innovation programme (grant agreement No 101001567).

Publisher Copyright:
© 2022 The Authors