Various metal deposition processes have been used for additive manufacturing of metals over the past decade. However, there is a need for an economically viable additive manufacturing process which can economically offer better mechanical properties, scalable deposition, and flexibility in terms of materials used for AM. In this presentation, Additive Friction Stir (AFS) will be explored as a novel AM method. Unique attributes will be considered along with resulting advantages and disadvantages. It is solid-state, which can yield parts with superior mechanical properties as compared to those produced by liquid-state metal deposition or spray forming processes. It is an open atmosphere process, allowing for extreme scalability. The process has both solid and powder filler material feed systems for fabrication of parts which have been used in materials ranging from magnesium to titanium. Further filler material flexibility exists in the powder feed system. Powders can vary in shape from spherical to flake and in size from sub-micron to millimeters. Powders can be combined in-situ to create new alloys or metal matrix composites. Non-fusion weldable materials can be used because the process is solid-state. All deposits are fully dense and do not require any additional processing for densification. Potential disadvantages include the inability to construct complex, finely featured products.
- Consider a new method for additive manufacturing and compare its advantages and disadvantages to existing processes
- Evaluate process performance in terms of size and scale, speed, flexibility, and quality
- Describe the primary differences between solid-state and fusion based additive manufacturing