Multi-layer multi-pass friction rolling additive manufacturing of Al alloy:Toward complex large-scale high-performance components  

作　　者：Haibin Liu Run Hou Chenghao Wu Ruishan Xie Shujun Chen 

机构地区：[1]College of Mechanical&Energy Engineering,Beijing University of Technology,Beijing 100124,China [2]Chongqing Research Institute of Beijing University of Technology,Chongqing 401121,China

出　　处：《International Journal of Minerals,Metallurgy and Materials》2025年第2期425-438,共14页矿物冶金与材料学报（英文版）

基　　金：supported by the National Key Research and Development Program of China(No.2022YFB3404700);the National Natural Science Foundation of China(Nos.52105313 and 52275299);the Research and Development Program of Beijing Municipal Education Commission,China(No.KM202210005036);the Natural Science Foundation of Chongqing,China(No.CSTB2023NSCQ-MSX0701);the National Defense Basic Research Projects of China(No.JCKY2022405C002).

摘　　要：At present,the emerging solid-phase friction-based additive manufacturing technology,including friction rolling additive man-ufacturing(FRAM),can only manufacture simple single-pass components.In this study,multi-layer multi-pass FRAM-deposited alumin-um alloy samples were successfully prepared using a non-shoulder tool head.The material flow behavior and microstructure of the over-lapped zone between adjacent layers and passes during multi-layer multi-pass FRAM deposition were studied using the hybrid 6061 and 5052 aluminum alloys.The results showed that a mechanical interlocking structure was formed between the adjacent layers and the adja-cent passes in the overlapped center area.Repeated friction and rolling of the tool head led to different degrees of lateral flow and plastic deformation of the materials in the overlapped zone,which made the recrystallization degree in the left and right edge zones of the over-lapped zone the highest,followed by the overlapped center zone and the non-overlapped zone.The tensile strength of the overlapped zone exceeded 90%of that of the single-pass deposition sample.It is proved that although there are uneven grooves on the surface of the over-lapping area during multi-layer and multi-pass deposition,they can be filled by the flow of materials during the deposition of the next lay-er,thus ensuring the dense microstructure and excellent mechanical properties of the overlapping area.The multi-layer multi-pass FRAM deposition overcomes the limitation of deposition width and lays the foundation for the future deposition of large-scale high-performance components.

关 键 词：aluminum alloy additive manufacturing SOLID-STATE friction stir welding multi-layer multi-pass 

分 类 号：TG339[金属学及工艺—金属压力加工]