Inventions 2024, 9(6), 116; https://doi.org/10.3390/inventions9060116 - 13 Nov 2024
Abstract
Emerging solid-state additive manufacturing (AM) technologies have recently garnered significant interest because they can prevent the defects that other metal AM processes may have due to sintering or melting. Additive friction stir deposition (AFSD), also known as MELD, is a solid-state AM technology
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Emerging solid-state additive manufacturing (AM) technologies have recently garnered significant interest because they can prevent the defects that other metal AM processes may have due to sintering or melting. Additive friction stir deposition (AFSD), also known as MELD, is a solid-state AM technology that utilises bar feedstocks as the input material and frictional–deformational heat as the energy source. AFSD offers high deposition rates and is a promising technique for achieving defect-free material properties like wrought aluminium, magnesium, steel, and titanium alloys. While it offers benefits in terms of productivity and material properties, its low technology readiness level prevents widespread adoption. Academics and engineers are conducting research across various subfields to better understand the process parameters, material properties, process monitoring, and modelling of the AFSD technology. Yet, it is also crucial to compile and compare the research findings from past studies on this new technology to gain a comprehensive understanding and pinpoint future research paths. This paper aims to present a comprehensive review of AFSD focusing on process parameters, material properties, monitoring, and modelling. In addition to examining data from existing studies, this paper identifies areas where research is lacking and suggests paths for future research efforts.
Full article
(This article belongs to the Special Issue Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies)
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Figure 1
<p>Schematic illustration of the AFSD process.</p> Full article ">Figure 2
<p>(<b>a</b>) Tool overview; (<b>b</b>) deposition tool schematics showing protrusion pairs [<a href="#B24-inventions-09-00116" class="html-bibr">24</a>].</p> Full article ">Figure 3
<p>A single-track wall manufactured by AFSD in AA6xxx series.</p> Full article ">Figure 4
<p>Onion skin observed on the top surface of a deposition.</p> Full article ">Figure 5
<p>Influences of feed rate override (FRO) on flash formation during AA6061 AFSD process under constant rotational speed.</p> Full article ">Figure 6
<p>AFSD process showing the relationship between the main input parameters, process signatures, and process outputs based on the literature survey.</p> Full article ">Figure 7
<p>(<b>a</b>) An illustration of the in situ monitoring system consisting of infrared and video cameras. The material flow behaviours of (<b>b</b>) Cu and (<b>c</b>) AA6061 [<a href="#B13-inventions-09-00116" class="html-bibr">13</a>].</p> Full article ">Figure 8
<p>The modified setup showing (<b>a</b>) thermocouple and cooling collars, and (<b>b</b>) thermocouple channels (licenced under CC BY 4.0) [<a href="#B12-inventions-09-00116" class="html-bibr">12</a>].</p> Full article ">Figure 9
<p>Temperature profile in the experiment (<b>a</b>) without an external heat source and (<b>b</b>) with a heat source. An image of the deposition (<b>c</b>) without an external heat source and (<b>d</b>) with a heat source experiments (licenced under CC BY 4.0) [<a href="#B65-inventions-09-00116" class="html-bibr">65</a>].</p> Full article ">Figure 10
<p>The classification of modelling techniques for the AFSD process.</p> Full article ">Figure 11
<p>Deformation using Lagrangian, Eulerian, and ALE solvers.</p> Full article ">Figure 12
<p>(<b>a</b>) Kernel function; (<b>b</b>) particle simulation by Stubbfield et al. (under CC BY 4.0 licence) [<a href="#B20-inventions-09-00116" class="html-bibr">20</a>].</p> Full article ">Figure 13
<p>(<b>a</b>) Typical bowl-shaped depression centre and the substrate-material mixing in the shear zone caused by tool rotations. (<b>b</b>) Image of the heat effected zone, and (<b>c</b>) image of the base plate.</p> Full article ">
<p>Schematic illustration of the AFSD process.</p> Full article ">Figure 2
<p>(<b>a</b>) Tool overview; (<b>b</b>) deposition tool schematics showing protrusion pairs [<a href="#B24-inventions-09-00116" class="html-bibr">24</a>].</p> Full article ">Figure 3
<p>A single-track wall manufactured by AFSD in AA6xxx series.</p> Full article ">Figure 4
<p>Onion skin observed on the top surface of a deposition.</p> Full article ">Figure 5
<p>Influences of feed rate override (FRO) on flash formation during AA6061 AFSD process under constant rotational speed.</p> Full article ">Figure 6
<p>AFSD process showing the relationship between the main input parameters, process signatures, and process outputs based on the literature survey.</p> Full article ">Figure 7
<p>(<b>a</b>) An illustration of the in situ monitoring system consisting of infrared and video cameras. The material flow behaviours of (<b>b</b>) Cu and (<b>c</b>) AA6061 [<a href="#B13-inventions-09-00116" class="html-bibr">13</a>].</p> Full article ">Figure 8
<p>The modified setup showing (<b>a</b>) thermocouple and cooling collars, and (<b>b</b>) thermocouple channels (licenced under CC BY 4.0) [<a href="#B12-inventions-09-00116" class="html-bibr">12</a>].</p> Full article ">Figure 9
<p>Temperature profile in the experiment (<b>a</b>) without an external heat source and (<b>b</b>) with a heat source. An image of the deposition (<b>c</b>) without an external heat source and (<b>d</b>) with a heat source experiments (licenced under CC BY 4.0) [<a href="#B65-inventions-09-00116" class="html-bibr">65</a>].</p> Full article ">Figure 10
<p>The classification of modelling techniques for the AFSD process.</p> Full article ">Figure 11
<p>Deformation using Lagrangian, Eulerian, and ALE solvers.</p> Full article ">Figure 12
<p>(<b>a</b>) Kernel function; (<b>b</b>) particle simulation by Stubbfield et al. (under CC BY 4.0 licence) [<a href="#B20-inventions-09-00116" class="html-bibr">20</a>].</p> Full article ">Figure 13
<p>(<b>a</b>) Typical bowl-shaped depression centre and the substrate-material mixing in the shear zone caused by tool rotations. (<b>b</b>) Image of the heat effected zone, and (<b>c</b>) image of the base plate.</p> Full article ">
