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<p><?tk 4?>Increasing the deposition rate in additive manufacturing (AM) techniques is critical to enhance production efficiency and reduce costs. In this context, additive friction stir deposition (AFSD) offers great potential for high-rate fabrication of metallic parts. It is essential to further develop this technique to expand the range of processable materials at high deposition rates. In this study, Al 7075-T651 parts were deposited by AFSD at a rate approximately 2.6 times higher than those reported in previous studies. The AFSD output parameters and the deposited part’s properties including mechanical properties and microstructure were evaluated and compared with literature. The results indicated increases in average force and torque by 70.9% and 36.7% respectively during the high-rate AFSD deposition process, along with 12% and 22.4% improvements in the average hardness and tensile strength, respectively for the AFSD part. The property changes were attributed to the reduced heat input during the process, finer grain microstructure, and a higher density of dislocations. Additionally, tribological properties of the high-rate as-deposited Al 7075 part were assessed and compared to the feedstock material. The results revealed improved wear resistance in the deposited part, particularly in the bottom layers, in most cases, which was primarily attributed to their higher toughness.</p> Graphical Abstract <p></p>

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Towards High-Rate Additive Friction Stir Deposition of Al 7075: Tribological, Microstructural, and Mechanical Properties

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Ehsan Bagheri,
  • Lijesh Koottaparambil,
  • Noushin Adibi,
  • Huan Ding,
  • Saeid Zavari,
  • Michael Khonsari,
  • Shengmin Guo

摘要

Increasing the deposition rate in additive manufacturing (AM) techniques is critical to enhance production efficiency and reduce costs. In this context, additive friction stir deposition (AFSD) offers great potential for high-rate fabrication of metallic parts. It is essential to further develop this technique to expand the range of processable materials at high deposition rates. In this study, Al 7075-T651 parts were deposited by AFSD at a rate approximately 2.6 times higher than those reported in previous studies. The AFSD output parameters and the deposited part’s properties including mechanical properties and microstructure were evaluated and compared with literature. The results indicated increases in average force and torque by 70.9% and 36.7% respectively during the high-rate AFSD deposition process, along with 12% and 22.4% improvements in the average hardness and tensile strength, respectively for the AFSD part. The property changes were attributed to the reduced heat input during the process, finer grain microstructure, and a higher density of dislocations. Additionally, tribological properties of the high-rate as-deposited Al 7075 part were assessed and compared to the feedstock material. The results revealed improved wear resistance in the deposited part, particularly in the bottom layers, in most cases, which was primarily attributed to their higher toughness.

Graphical Abstract