TY - JOUR

T1 - Fundamental study of multi-track friction surfacing deposits for dissimilar aluminum alloys with application to additive manufacturing

AU - Soujon, Malte

AU - Kallien, Zina

AU - Roos, Arne

AU - Zeller-Plumhoff, Berit

AU - Klusemann, Benjamin

N1 - 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

PY - 2022/7/1

Y1 - 2022/7/1

N2 - 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.

AB - 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.

KW - Engineering

KW - Additive manufacturing

KW - Defect analysis

KW - Hybrid friction diffusion bonding

KW - Multi-track friction surfacing

KW - Tensile properties

KW - microCT

UR - https://www.mendeley.com/catalogue/0aa50613-bf7c-362e-91a2-880d5876c62a/

UR - http://www.scopus.com/inward/record.url?scp=85131457826&partnerID=8YFLogxK

U2 - 10.1016/j.matdes.2022.110786

DO - 10.1016/j.matdes.2022.110786

M3 - Journal articles

VL - 219

JO - Materials and Design

JF - Materials and Design

SN - 0264-1275

M1 - 110786

ER -