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<p>Inevitable welding fumes/slags and high energy costs induced by fusion repairing technologies brought about a pressing concern to propose an environmentally friendly alternative for the repair of worn-out aluminum alloy components. Sparked by its solid-state cleaner repairing characteristics, wire-based friction stir additive remanufacturing (W-FSARM) was proposed and exploited to realize volumetric defects repairing with waste minimization. With the high-speed rotation of the pin, filler materials were thermo-plasticized within the W-FSARM tool and flowed downward into the defects to blend with the substrate. The material flow and filling behavior contributed to sound-repaired joints, ensuring a high-quality interfacial bonding. Prefabricated volumetric defects with the width of 8 mm and depth of 1&#xa0;mm were successfully repaired on 2219 aluminum alloy components. The grains in repaired zone were equiaxed grains with an average grain size of only 2.35 ± 0.04 μm. The ultimate tensile strength of the repaired joints reached 90% of the base materials. This indicated that the W-FSARM technique can eco-friendly repair surficial defects without waste production and realize improved structural integrity towards life cycle extension.</p>

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Wire-based friction stir additive remanufacturing of 2219 aluminum alloy components

  • 期刊论文

  • 发表日期：

    2025年4月12日

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  • Yongxian Huang,
  • Yuming Xie,
  • Jialin Chen,
  • Junchen Li,
  • Yaobang Zhao,
  • Xiangchen Meng

摘要

Inevitable welding fumes/slags and high energy costs induced by fusion repairing technologies brought about a pressing concern to propose an environmentally friendly alternative for the repair of worn-out aluminum alloy components. Sparked by its solid-state cleaner repairing characteristics, wire-based friction stir additive remanufacturing (W-FSARM) was proposed and exploited to realize volumetric defects repairing with waste minimization. With the high-speed rotation of the pin, filler materials were thermo-plasticized within the W-FSARM tool and flowed downward into the defects to blend with the substrate. The material flow and filling behavior contributed to sound-repaired joints, ensuring a high-quality interfacial bonding. Prefabricated volumetric defects with the width of 8 mm and depth of 1 mm were successfully repaired on 2219 aluminum alloy components. The grains in repaired zone were equiaxed grains with an average grain size of only 2.35 ± 0.04 μm. The ultimate tensile strength of the repaired joints reached 90% of the base materials. This indicated that the W-FSARM technique can eco-friendly repair surficial defects without waste production and realize improved structural integrity towards life cycle extension.