Microstructure Control with a Combined Metal Additive Manufacturing and Deformation Processing
2022-01-0323
03/29/2022
- Event
- Content
- Direct metal additive manufacturing provides great flexibility in 3D shaping as compared with traditional manufacturing processes of metal casting, deformation followed by machining and joining for obtaining final production shape. On the other hand, it suffered from its dendric microstructure produced during solidification. This study reports the development of a new combined metal additive and deformation processes to take advantages and reduce/eliminate the drawback from individual process. There are many forms of direct metal deposition processes mainly categorized by the heating source and heat application method used. Similarly, there are also many deformation processes that can provide a wide range of applied stress, strain, strain rate and temperature, which ultimately determine the final microstructure and property of the product. One constraint for selection of deformation process is the need to provide local deformation to allow flexible 3D printing and forming. To demonstrate the feasibility of such concept, in this study, a common industry MIG welding process is used for metal deposition from solid wire to solid 3D shape, and Friction Stir Process (FSP) is used for local severe plastic deformation at controlled strain, strain rate and temperature within a relatively small processing volume. Commercial aluminum wires are used for this study. The processing parameters to be investigated include the MIG power rare, nuzzle moving speed, wire feeding rate, the friction stirring head geometry parameters, rotation speed and moving velocity, along with the cooling rate. The grain size distribution over different additive layers are measured. Wide range of grain sizes, including submicron fine grain size are obtained to correlate with the thermomechanical conditions. The advantages and potential application of the process of MIG+FSP is discussed.
- Citation
- ELALEM, A., and Wu, X., "Microstructure Control with a Combined Metal Additive Manufacturing and Deformation Processing ," SAE Technical Paper 2022-01-0323, 2022, .