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<p>This study investigates the process data, microstructure, and mechanical behavior of multi-layer AA7075 stacks processed via friction surfacing. While the layer width remained consistent, there was a noticeable trend of decreasing thickness and deposition efficiency, particularly after the third layer, attributed to changes in heat transfer conditions. The AA7075 stack exhibited a uniform, fine-grained microstructure, with no significant differences between the initial and final layers. The ultimate tensile strength averaged 466 ± 22 MPa, reflecting an 18% reduction compared to the feedstock material, whereas the maximum elongation of 14.56 ± 3.42% exhibited a 37% improvement. Increased thermal cycling with each deposited layer resulted in slight decreases in strength and hardness in the initial layers. These changes are associated with variations in precipitate distribution along the building direction. Hardness measurements showed a consistent distribution across the layer width. Future work will extend the study to other aluminum alloys and geometries for broader industrial applicability.</p>

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Comprehensive analysis of multi-layer friction surfacing of 7075 aluminum alloy: manufacturing, microstructure, and mechanical properties

  • 期刊论文

  • 发表日期：

    2025年4月14日

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  • Javier Vivas,
  • Marcelo Roldán,
  • Mariane Chludzinski,
  • Evgeny Modin,
  • Andrey Chuvilin,
  • Oier Zubiri,
  • Maria del Carmen Taboada,
  • Egoitz Aldanondo

摘要

This study investigates the process data, microstructure, and mechanical behavior of multi-layer AA7075 stacks processed via friction surfacing. While the layer width remained consistent, there was a noticeable trend of decreasing thickness and deposition efficiency, particularly after the third layer, attributed to changes in heat transfer conditions. The AA7075 stack exhibited a uniform, fine-grained microstructure, with no significant differences between the initial and final layers. The ultimate tensile strength averaged 466 ± 22 MPa, reflecting an 18% reduction compared to the feedstock material, whereas the maximum elongation of 14.56 ± 3.42% exhibited a 37% improvement. Increased thermal cycling with each deposited layer resulted in slight decreases in strength and hardness in the initial layers. These changes are associated with variations in precipitate distribution along the building direction. Hardness measurements showed a consistent distribution across the layer width. Future work will extend the study to other aluminum alloys and geometries for broader industrial applicability.