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Hybrid Manufacturing Using Friction Stir Additive, Structured Light Scanning and CNC Machining

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  • schoolOptimization

This presentation describes the integration of three complementary technologies to enable hybrid manufacturing. First, friction stir additive manufacturing is applied for solid-state deposition of a 6061-T6 aluminum preform that contains the desired part geometry. Second, structured light scanning is used to measure the preform and supporting pallet simultaneously. A coordinate system is assigned to the measurement using the pallet features and this result is used as the stock model for the computer-aided manufacturing toolpath generation. The pallet is then transferred by a six degree-of-freedom robot to the five-axis computer numerically controlled milling machine to achieve the designer’s intent for geometry, accuracy and surface finish using the tool paths and optimized machining parameters. Because the pallet is automatically located within the machine tool work volume, on-machine probing is not required. The pallet coordinate system serves as both the part and tool path coordinate system and it is already known relative to the machine tool coordinate system. Measurements of the final part are presented, including microstructure evaluation. 

Learning Objectives:

  • Understand the value of including preform measurements to automatically establish the additive manufacturing preform coordinate system for toolpath generation and machining.
  • Understand the advantages of friction stir additive manufacturing.
  • Understand physics-based selection of machining parameters.