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Results of Evaluation of Solid-State Frictional Stir Additive Manufacturing for the United States Navy

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A visually rich presentation, making one-to-one parameter performance comparisons between standard billet and Solid-State Frictional Stir Additive Manufacturing (FSAM) macro constructs resulting from 2022 efforts. Researchers at the U.S. Naval Information Warfare Center Pacific in San Diego are presently tasked with leveraging next-generation technologies, such as additive manufacturing, to increase sustainment capabilities in support of the modern warfighter. In this presentation the authors will outline three specific applications of the MELD process (also known as FSAM), including the 3D printing of long-lead raw casting replacements, the repair of legacy components currently without a repair strategy, and Navy patented approach for extending the life of legacy components by depositing a sacrificial anodic material directly onto a targeted area of the existing component’s geometry. The FSAM process is a solid-state metal additive technology that utilizes a non- consumable rotating tool to plastically deform solid, wrought bar feedstock as means to enable both additive manufacturing, joining, and repair of large metal components. The details of this effort including motivation, mechanical performance, qualification and acceptance, and next steps will be discussed.

Learning Objectives:

  • Evaluate mechanical performance parameters of FSAM as a technology for AM constructs, against similar constructs previously rendered using billet material.
  • Evaluate FSAM as a technology for AM repair previously rendered using hot processes, such as
  • Evaluate corrosion resistance performance parameters of FSAM as a technology for AM constructs, against similar constructs previously rendered using billet material.
  • Stephen Cox, CMfgE
    Chief Engineer, RESTORE Lab
    Naval Information Warfare Center Pacific, NIWC-PAC, NAVWAR, US Navy
  • Chase Cox, PhD
    Vice President
    MELD Manufacturing Corporation