Gradient process parameter optimization in additive friction stir deposition of aluminum alloys

• Published in: International journal of machine tools & manufacture 2024-02, Vol.195, p.104113, Article 104113
• Main Authors: Jin, Yuqi, Wang, Tianhao, Liu, Tingkun, Yang, Teng, Dowden, Shelden, Neogi, Arup, Dahotre, Narendra B.
• Format: Article
• Language: English
• Subjects: Additive friction stir deposition (AFSD); Aluminum alloy; Parameter optimization; Ultrasound
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2023.104113

As one of the most novel additive manufacturing methods, currently selection and optimization of processing parameters in additive friction stir deposition (AFSD) have mainly relied on experiments and subsequent characterization of microstructural and mechanical properties. Such approaches are both time- and resource-consuming. Therefore, an ultrasound elastography enhanced gradient process parameter optimization method was applied in the present work to obtain a window of optimized processing parameters for AFSD processing of aluminum alloy by varying both rotational and linear deposition speeds. The quality of AFSD processed layer was investigated for physical nature of surface, dynamic elastic modulus, and microstructural aspects in cross-sections of the deposited layer. The efficiency in exploring process parameters was significantly enhanced by implementing a high-throughput screening experimental design based on application of gradient process parameters and continuous ultrasound elastographs. In addition, the applied ultrasonic elastography technique assisted in evaluating the homogeneity in microstructure and mechanical properties of AFSD sample over the entire gradients of the process parameters. The techniques adopted in current work can be further extended to identify suitable parameters for AFSD fabrication of components with desired mechanical properties such as hardness, fatigue, etc. [Display omitted] •An Ultrasound Elastography Enhanced Gradient Process Parameter Optimization (UEGPPO) was proposed.•The validity of UEGPPO approach was established through evaluating microstructures and physical parameters.•Parameter windows of elasticity and physical aspects were obtained by four samples varying tool rotation and linear speeds.•The insight into outcome of UEGPPO approach was obtained in a physical space through solid and fluid mechanics.•Heat deviation induced viscous behaviors lead to different grain boundary morphology, effective strain and elastic modulus.