Yakubov Vladislav, Ostergaard Halsey, Hughes James, Yasa Evren, Karpenko Michail, Proust Gwénaëlle, Paradowska Anna M
School of Civil Engineering, The University of Sydney, Sydney, NSW 2006, Australia.
Australian Nuclear Science and Technology Organisation, Kirrawee, NSW 2234, Australia.
Materials (Basel). 2024 Jul 12;17(14):3457. doi: 10.3390/ma17143457.
Additive friction stir deposition (AFSD) is an emerging solid-state additive manufacturing process with a high deposition rate. Being a non-fusion additive manufacturing (AM) process, it significantly eliminates problems related to melting such as cracking or high residual stresses. Therefore, it is possible to process reactive materials or high-strength alloys with high susceptibility to cracking. Although the residual stresses are lower in this process than with the other AM processes, depending on the deposition path, geometry, and boundary conditions, residual stresses may lead to undesired deformations and deteriorate the dimensional accuracy. Thermal cycling during layer deposition, which also depends on the geometry of the manufactured component, is expected to affect mechanical properties. To this day, the influence of the deposit geometry on the residual stresses and mechanical properties is not well understood, which presents a barrier for industry uptake of this process for large-scale part manufacturing. In this study, a stepped structure with 4, 7, and 10 passes manufactured via AFSD is used to investigate changes in microstructure, residual stress, and mechanical property as a function of the number of passes. The microstructure and defects are assessed using scanning electron microscopy and electron backscatter diffraction. Hardness maps for each step are created. The residual stress distributions at the centreline of each step are acquired via non-destructive neutron diffraction. The valuable insights presented here are essential for the successful utilisation of AFSD in industrial applications.
叠加摩擦搅拌沉积（AFSD）是一种新兴的具有高沉积速率的固态增材制造工艺。作为一种非熔合增材制造（AM）工艺，它显著消除了与熔化相关的问题，如开裂或高残余应力。因此，能够加工对开裂敏感的活性材料或高强度合金。尽管该工艺中的残余应力比其他增材制造工艺低，但根据沉积路径、几何形状和边界条件，残余应力可能会导致不期望的变形并降低尺寸精度。层沉积过程中的热循环（这也取决于所制造部件的几何形状）预计会影响机械性能。时至今日，沉积物几何形状对残余应力和机械性能的影响尚未得到很好的理解，这为该工艺在大规模零件制造中的工业应用设置了障碍。在本研究中，使用通过AFSD制造的具有4道、7道和10道的阶梯结构来研究微观结构、残余应力和机械性能随道次数量的变化。使用扫描电子显微镜和电子背散射衍射来评估微观结构和缺陷。创建每个步骤的硬度图。通过无损中子衍射获取每个步骤中心线处的残余应力分布。这里给出的有价值的见解对于在工业应用中成功利用AFSD至关重要。
