Use of Friction Surfacing for Additive Manufacturing
05 Feb 2013-Materials and Manufacturing Processes (Taylor & Francis Group)-Vol. 28, Iss: 2, pp 189-194
TL;DR: In this paper, sound multi-layered deposits in various ferrous materials were realized using friction surfacing in both single-and multi-track approaches, and samples with fully enclosed internal cavities were also successfully produced.
Abstract: In this work, we explore the possibility of utilizing friction surfacing, an emerging solid-state surface coating process, for layer-by-layer manufacture of three-dimensional metallic parts. One possibility in this regard (single-track friction surfacing) is to utilize friction surfacing for depositing a track or layer of material (sufficiently wide to cover the entire layer area), which is subsequently shaped to its corresponding slice counter using CNC machining. Another possibility (multi-track friction surfacing) is to generate a layer from multiple overlapping tracks of friction surfaced material, which is subsequently shaped as required using CNC machining. In the current work, sound multi-layered deposits in various ferrous materials were realized using friction surfacing in both single- and multi-track approaches. Samples with fully enclosed internal cavities and those consisting of different materials in different layers were also successfully produced. The deposits showed fine-grain wrought micr...
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TL;DR: In this paper, the feasibility of deposition of copper on the mild steel using friction surfacing method was reported, where commercial mild steel was chosen as the substrate and commercial pure copper as the consumable rod.
15 citations
TL;DR: In this article, the solid-state coating of AISI316 stainless steel over EN24 medium carbon steel by friction surfacing process was successfully made in the present work to obtain the solidstate coating.
Abstract: An investigation was successfully made in the present work to obtain the solid-state coating of AISI316 stainless steel over EN24 medium carbon steel by friction surfacing process. Spindle speed, a...
15 citations
Cites background from "Use of Friction Surfacing for Addit..."
...Autostrengthening is a natural feature of the friction surfacing practice.([3,4]) Sekharbabu et al....
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01 Feb 2014-Metallurgical and Materials Transactions B-process Metallurgy and Materials Processing Science
TL;DR: In this article, a rotary friction welding machine and employing alloy 718 consumable rods in solution treated condition, cylindrical-shaped multi-layer friction deposits (10mm diameter) were successfully produced.
Abstract: Friction Freeform Fabrication is a new solid-state additive manufacturing process. The present investigation reports a detailed study on the prospects of this process for additive part fabrication in superalloy Inconel 718. Using a rotary friction welding machine and employing alloy 718 consumable rods in solution treated condition, cylindrical-shaped multi-layer friction deposits (10 mm diameter) were successfully produced. In the as-deposited condition, the deposits showed very fine grain size with no grain boundary δ phase. The deposits responded well to direct aging and showed satisfactory room-temperature tensile properties. However, their stress rupture performance was unsatisfactory because of their layered microstructure with very fine grain size and no grain boundary δ phase. The problem was overcome by heat treating the deposits first at 1353 K (1080 °C) (for increasing the grain size) and then at 1223 K (950 °C) (for precipitating the δ phase). Overall, the current study shows that Friction Freeform Fabrication is a very useful process for additive part fabrication in alloy 718.
15 citations
TL;DR: In this article , the authors provide an overview of various aspects of AM materials highlighting the progress made especially over the past two decades, highlighting the innovative applications of AM open up newer challenges and thus avenues for focused attention.
Abstract: Tremendous growth has been witnessed in the field of additive manufacturing (AM) technology over the last few decades. It offers a plethora of applications and is already being utilized in almost every sphere of life. Owing to inherent differences between each AM technique, newer fields of research consistently emerge and demand attention. Also, the innovative applications of AM open up newer challenges and thus avenues for focused attention. One such avenue is AM materials. Raw material plays an important role in determining the properties of fabricated part. The type and form of raw material largely depend on the type of AM fabricators. There is a restriction on material compatibility with most of the established AM techniques. This review aims to provide an overview of various aspects of AM materials highlighting the progress made especially over the past two decades.
15 citations
02 Jul 2019
TL;DR: In this paper, the Al alloy 5083 was deposited on an AA2024 substrate and the resulting microstructure including the layer interfaces were investigated by metallographic methods as well as SEM-based techniques including EBSD.
Abstract: Friction Surfacing Layer Deposition (FSLD) is a friction-based process capable of depositing similar or dissimilar materials on a substrate surface. The process is based on the plastic deformation of a rotating metallic consumable rod, which is pressed against the substrate material under an applied axial load. Frictional heat is then generated at the interface between the rod and the substrate due to their relative motion, resulting in a layer of plasticized material that forms a continuous deposit by the translation of the stud along the substrate. On top of this deposit more layers can be realized to build up a multi-layered wall in a solid-state fashion. In this study, the Al alloy 5083 was deposited on an AA2024 substrate. The resulting microstructure including the layer interfaces were investigated by metallographic methods as well as SEM-based techniques including EBSD. Hardness mapping was used for examining local mechanical properties. According to the process monitoring, the quality of the layers is very reproducible. EBSD maps show a sound bonding around the interface between the first layer and the substrate with its upper part showing recrystallized grains where the lower part consists of partially recrystallized grains due to the thermal and mechanical impact, while the heat-affected changes little. All layers exhibit fine, equiaxed recrystallized grains with a typical grain size of 4-5 microns. The variation in size and shape over the height of the structure are limited. Consequently, the multilayered deposit exhibits very homogenous local mechanical properties, i.e., microhardness. In summary, FSLD has shown the feasibility and required flexibility for multilayer depositing. The process may be an effective alternative to melting-based additive manufacturing methods for specific applications.
14 citations
References
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Book•
01 Jan 2009
TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.
Abstract: Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker, more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of AM applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Authors Ian Gibson, David W. Rosen and Brent Stucker explain these issues, as well as: Providing a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches Discussing the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use components Introducing systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing is the perfect book for researchers, students, practicing engineers, entrepreneurs, and manufacturing industry professionals interested in additive manufacturing.
3,087 citations
"Use of Friction Surfacing for Addit..." refers background in this paper
...Finally, part fabrication with these processes typically takes a very long time as the deposition rates are very low (less than 1 gram=minute) [2]....
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Journal Article•
127 citations
01 Apr 2007
TL;DR: The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy.
Abstract: Transactions of The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy, materials engineering, physical, chemical and mechanical metallurgy, welding science and technology, surface engineering and characterisation, materials development, thermodynamics and kinetics, materials modelling and to other allied branches of metallurgy and materials engineering.
116 citations
TL;DR: In this paper, the authors describe the events that the matrix and carbides experience as the coating material pass from the coating rod to the substrate, in forming the coating, and the coating is observed to harden automatically within a few seconds of being deposited onto the cold substrate.
Abstract: This paper is concerned with the friction surfacing of high-speed steels, BM2, BT15 and ASP30 onto plain carbon steel plate. The events that the matrix and carbides experience as the coating material pass from the coating rod to the substrate, in forming the coating, is described. The coating is observed to harden automatically within a few seconds of being deposited onto the cold substrate. This autohardening is observed to be an inherent feature of the friction surfacing process and the only post-coating heat treatment required is tempering, as with traditionally hardened high-speed steels. The mechanism of autohardening is discussed in terms of the mechtrode/coating/substrate thermal system.
85 citations
"Use of Friction Surfacing for Addit..." refers background in this paper
..., around 1200 C in the case of alloy 410) [15, 16, 19]....
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...2b, friction surfaced deposits typically show lack of bonding at the deposit edges, due to material roll-over [13, 15]....
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Patent•
04 Oct 2000
TL;DR: In this paper, friction heating and bonding are used to consolidate sequentially applied metals, plastics or composites to previously deposited material so as to form a bulk deposit in a desired shape.
Abstract: Friction heating and bonding are used to consolidate sequentially applied metals, plastics or composites to previously deposited material so as to form a bulk deposit in a desired shape. Monolithic or composite sheets, tapes and filaments can be consolidated using the approach. A system according to the invention includes a source of friction; a mechanism for applying a forging load between a feedstock power supply and a work surface; a work-head, which may have various configurations depending on the geometry of the feedstock to be used; a material feeding system; and a computer-controlled actuation system which controls the placement of material increments added to an object being built. A computer model of the object to be built is used to generate commands to produce the object additively and automatically. The approach provides a solid, freeform fabrication technique that requires no tooling, operates in the solid state, and creates a bond directly at the faying surfaces (i.e., acts only at the location where bonding/consolidation of the material increments is desired).
80 citations