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<p>Friction stir-based solid-state additive manufacturing (SSAM) has emerged as an alternative to fusion-based additive manufacturing (FBAM) for large-scale aerospace, defense, and biomedical applications. While Ti6Al4V is widely manufactured using FBAM processes like Laser Powder Bed Fusion (LPBF), research on solid-state processes such as Friction Stir Metal Deposition (FSMD) remains limited. This study compares FSMD with LPBF in terms of surface characteristics, dimensional tolerances, microstructure-property relationships, and sustainability. Results show FSMD provides better surface roughness but requires post-machining of side edges, while LPBF achieves better dimensional accuracy (± 2%). FSMD exhibits a lamellar-equiaxed structure with 0.2% beta phase and 37.3% high-angle grain boundaries (HAGBs), whereas LPBF forms a fine martensitic structure with 1% beta phase and 48.8% HAGBs. These microstructural differences influence mechanical properties, with FSMD showing lower strength (768&#xa0;MPa yield strength, 830&#xa0;MPa ultimate tensile strength) and elongation (6.7%) compared to LPBF (928&#xa0;MPa yield strength, 1125&#xa0;MPa ultimate tensile strength, 8.7% elongation). However, due to solid-state nature of FSMD process, it resulted in samples with reduced porosity (0.13%) and lower residual stresses (−&#xa0;50&#xa0;MPa) than LPBF. FSMD proved significantly more sustainable, consuming only 0.26 kWh and costing $3.4 per part versus 9.27 kWh and $54.6 for LPBF. Its lower thermal input and resource efficiency make FSMD suitable for high-volume, less complex geometries, while LPBF remains suited for highly complex designs at a higher cost. This study highlights the energy, cost, and material efficiency of the FSMD process, showcasing its potential as a sustainable manufacturing process for widely used titanium alloy components.</p> Graphical abstract <p></p>

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Comparative assessment of fusion-based and solid-state additive manufacturing of Ti6Al4V: microstructure, properties, and sustainability

  • 期刊论文

  • 发表日期：

    2025年8月21日

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  • Bhavesh Chaudhary,
  • Bhanupratap Gaur,
  • Neeraj Kumar Mishra,
  • Amber Shrivastava,
  • Soham Mujumdar

摘要

Friction stir-based solid-state additive manufacturing (SSAM) has emerged as an alternative to fusion-based additive manufacturing (FBAM) for large-scale aerospace, defense, and biomedical applications. While Ti6Al4V is widely manufactured using FBAM processes like Laser Powder Bed Fusion (LPBF), research on solid-state processes such as Friction Stir Metal Deposition (FSMD) remains limited. This study compares FSMD with LPBF in terms of surface characteristics, dimensional tolerances, microstructure-property relationships, and sustainability. Results show FSMD provides better surface roughness but requires post-machining of side edges, while LPBF achieves better dimensional accuracy (± 2%). FSMD exhibits a lamellar-equiaxed structure with 0.2% beta phase and 37.3% high-angle grain boundaries (HAGBs), whereas LPBF forms a fine martensitic structure with 1% beta phase and 48.8% HAGBs. These microstructural differences influence mechanical properties, with FSMD showing lower strength (768 MPa yield strength, 830 MPa ultimate tensile strength) and elongation (6.7%) compared to LPBF (928 MPa yield strength, 1125 MPa ultimate tensile strength, 8.7% elongation). However, due to solid-state nature of FSMD process, it resulted in samples with reduced porosity (0.13%) and lower residual stresses (− 50 MPa) than LPBF. FSMD proved significantly more sustainable, consuming only 0.26 kWh and costing $3.4 per part versus 9.27 kWh and $54.6 for LPBF. Its lower thermal input and resource efficiency make FSMD suitable for high-volume, less complex geometries, while LPBF remains suited for highly complex designs at a higher cost. This study highlights the energy, cost, and material efficiency of the FSMD process, showcasing its potential as a sustainable manufacturing process for widely used titanium alloy components.

Graphical abstract