Potential and challenges for large-scale near-net-shaping of 7xxx aerospace grade aluminum via additive friction stir deposition
Hang Z. Yu, Greg D. Hahn
Abstract
This letter examines the potential and challenges of using additive friction stir deposition for large-scale near-net-shaping of 7xxx Al alloys, particularly AA7075 and AA7050. Compared to fusion-based additive manufacturing, which is unable to print these alloys without feedstock modification or composition change, additive friction stir deposition is an emerging solid-state additive process with a thermomechanical processing nature that can render fully-dense AA7075 and AA7050 in the as-deposited state. More importantly, wrought-like tensile properties have been demonstrated in the deposited AA7075 based on the original composition. The process is well-suited for large-scale printing due to its high build rate and scalability. Significant challenges nevertheless exist in process and post-process control, in addition to the impurity from lubrication.