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<p>This research work presents a comprehensive evaluation of solid-state additive manufacturing (SSAM) processes developed under the domain of friction stir engineering (FSE), which has emerged as a promising route to overcome the limitations of conventional fusion-based additive manufacturing. SSAM eliminates melting by utilizing frictional heat and plastic deformation for layer-wise material consolidation, enabling dense, defect-free metallic builds with fine-grained microstructures. Building on these principles, FSE unifies solid-state joining and additive manufacturing concepts into a hybrid additive manufacturing framework, facilitating sustainable and high-integrity material fabrication. Within this category, five friction-based additive techniques were examined: friction-based powder bed additive deposition (FPBAD), preheated substrate variant of FPBAD (FPBAD-P), friction-based powder fed additive deposition (FPFAD), friction stir additive deposition (FSAD), and additive friction deposition (AFD). Each process was comparatively analyzed based on its operational parameters, processing principles, deposition performance, and practical applicability. Results reveal that the preheated powder bed additive deposition process achieved the highest deposition quality with superior layer uniformity and bonding efficiency, followed by FSAD, while the powder-fed approach exhibited variable uniformity due to feeding inconsistencies. Comparative study established the fundamental relationship between feeding mechanisms, principle of material deposition/consolidation, and build characteristics including its geometry as well as macrostructures, offering valuable insight into optimizing friction stir-based SSAM systems for advanced hybrid manufacturing applications.</p>

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Comparative evaluation of friction-based solid-state additive deposition configurations for metallic part fabrication

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Manu Srivastava,
  • Sandeep Rathee,
  • Pulak Mohan Pandey,
  • Shazman Nabi,
  • Pushkal Badoniya,
  • Amit Soni

摘要

This research work presents a comprehensive evaluation of solid-state additive manufacturing (SSAM) processes developed under the domain of friction stir engineering (FSE), which has emerged as a promising route to overcome the limitations of conventional fusion-based additive manufacturing. SSAM eliminates melting by utilizing frictional heat and plastic deformation for layer-wise material consolidation, enabling dense, defect-free metallic builds with fine-grained microstructures. Building on these principles, FSE unifies solid-state joining and additive manufacturing concepts into a hybrid additive manufacturing framework, facilitating sustainable and high-integrity material fabrication. Within this category, five friction-based additive techniques were examined: friction-based powder bed additive deposition (FPBAD), preheated substrate variant of FPBAD (FPBAD-P), friction-based powder fed additive deposition (FPFAD), friction stir additive deposition (FSAD), and additive friction deposition (AFD). Each process was comparatively analyzed based on its operational parameters, processing principles, deposition performance, and practical applicability. Results reveal that the preheated powder bed additive deposition process achieved the highest deposition quality with superior layer uniformity and bonding efficiency, followed by FSAD, while the powder-fed approach exhibited variable uniformity due to feeding inconsistencies. Comparative study established the fundamental relationship between feeding mechanisms, principle of material deposition/consolidation, and build characteristics including its geometry as well as macrostructures, offering valuable insight into optimizing friction stir-based SSAM systems for advanced hybrid manufacturing applications.