Study on Influence Mechanism of Process Parameters on Mechanical Properties of Additive Friction Stir Deposited Aluminum Alloy

doi:10.3901/JME.2025.20.062

Abstract

Abstract: Optimizing additive friction stir deposition manufacturing processes has been an urgent need. In order to overcome the problem of uneven distributed mechanical performance, a study of additive friction stir deposition manufacturing process for 6061 aluminum alloy has been conducted. The effects of traveling speed and shoulder height on the macroscopic morphology, microstructure, and mechanical properties of the deposited aluminum alloy are analyzed. A physical model of material filling during the deposition process is also established. The results show that internal weak bonding in deposition layer is the main cause of the decrease in tensile performance along the deposition direction. When weak bonding occurred, the arc-shaped pattern on the surface of the deposition layer became shallower or disappeared in local areas. The formation of weak bonding can be suppressed by setting the actual feeding rate greater than the theoretical feeding rate required to just fill the preset gap in a single rotation cycle of the shoulder, which improve the metallurgical bonding quality and mechanical properties. The proposed calculation methods for material fill volume and feed rate based on the deposition process of plasticized materials provide a theoretical basis for a deeper understanding of the friction stir additive process and for improving deposition quality.

Key words: additive manufacturing, 6061 aluminum alloy, microstructure, weak bonding

CLC Number:

TG455

LI Xinxian, ZHU Hongbin, LI Huijun, HE Bin, ZHONG Hua, HUANG Yiming, CUI Lei. Study on Influence Mechanism of Process Parameters on Mechanical Properties of Additive Friction Stir Deposited Aluminum Alloy[J]. Journal of Mechanical Engineering, 2025, 61(20): 62-71.

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