Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing
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Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing. / Rath, Lars; Kallien, Zina; Roos, Arne et al.
In: The International Journal of Advanced Manufacturing Technology, Vol. 125, No. 5-6, 03.2023, p. 2091-2102.Research output: Journal contributions › Journal articles › Research › peer-review
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TY - JOUR
T1 - Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing
AU - Rath, Lars
AU - Kallien, Zina
AU - Roos, Arne
AU - dos Santos, Jorge F.
AU - Klusemann, Benjamin
N1 - Publisher Copyright: © 2023, The Author(s).
PY - 2023/3
Y1 - 2023/3
N2 - Friction surfacing (FS) is a solid-state layer deposition process for metallic materials at temperatures below their melting point. While the bonding of the deposited layers to the substrate is proven suitable for coating applications, so far the mechanical properties of additively manufactured stacks have not been systematically investigated. In particular, the effect of successive deposited FS layers, i.e., repetitive thermo-mechanical loading, on the interface properties as well as anisotropy and strength of the deposited stack is unknown. For this purpose, the mechanical properties of FS deposited multi-layer stacks from dissimilar aluminum alloys have been investigated, characterizing layer-to-layer as well as layer-to-substrate bonding interfaces via micro-flat tensile testing. Furthermore, directional dependencies in the stack and failure mechanisms are analyzed. The results show a homogeneous, fine-grained microstructure with average grain sizes between 4.2 and 4.6 μ m within the deposited material. The resulting tensile properties with no significant directional dependency present an ultimate tensile strength between 320 and 326 MPa exceeding the strength of the AA5083 H112 consumable base material. No difference was obtained in terms of layer-to-layer or layer-to-substrate interface strength. Furthermore, homogeneous hardness was observed within the deposited structure, which is in the range of AA5083 base material’s hardness of 91 HV. The results indicate that the FS process in conjunction with the material used is suitable for additively generated structures and highlight the potential of this solid-state layer deposition technology.
AB - Friction surfacing (FS) is a solid-state layer deposition process for metallic materials at temperatures below their melting point. While the bonding of the deposited layers to the substrate is proven suitable for coating applications, so far the mechanical properties of additively manufactured stacks have not been systematically investigated. In particular, the effect of successive deposited FS layers, i.e., repetitive thermo-mechanical loading, on the interface properties as well as anisotropy and strength of the deposited stack is unknown. For this purpose, the mechanical properties of FS deposited multi-layer stacks from dissimilar aluminum alloys have been investigated, characterizing layer-to-layer as well as layer-to-substrate bonding interfaces via micro-flat tensile testing. Furthermore, directional dependencies in the stack and failure mechanisms are analyzed. The results show a homogeneous, fine-grained microstructure with average grain sizes between 4.2 and 4.6 μ m within the deposited material. The resulting tensile properties with no significant directional dependency present an ultimate tensile strength between 320 and 326 MPa exceeding the strength of the AA5083 H112 consumable base material. No difference was obtained in terms of layer-to-layer or layer-to-substrate interface strength. Furthermore, homogeneous hardness was observed within the deposited structure, which is in the range of AA5083 base material’s hardness of 91 HV. The results indicate that the FS process in conjunction with the material used is suitable for additively generated structures and highlight the potential of this solid-state layer deposition technology.
KW - Additive manufacturing
KW - Anisotropy
KW - Dissimilar aluminum alloys
KW - Mechanical properties
KW - Multi-layer friction surfacing
KW - Engineering
UR - http://www.scopus.com/inward/record.url?scp=85146389745&partnerID=8YFLogxK
UR - https://www.mendeley.com/catalogue/9c9a9da3-da80-3014-a211-3fb95a51d573/
U2 - 10.1007/s00170-022-10685-3
DO - 10.1007/s00170-022-10685-3
M3 - Journal articles
AN - SCOPUS:85146389745
VL - 125
SP - 2091
EP - 2102
JO - The International Journal of Advanced Manufacturing Technology
JF - The International Journal of Advanced Manufacturing Technology
SN - 0268-3768
IS - 5-6
ER -