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 spatio-temporal temperature field during friction surfacing (FS) is investigated within the substrate via a combined experimental-numerical approach, and a robust and efficient thermal process model accounting for the contributions of friction and plasticity as heat input is presented.
Abstract: Friction surfacing (FS) is a solid state coating technology for similar and dissimilar metallic materials. The coating of the substrate with a consumable material is enabled due to frictional heat and plastic deformation and is performed below the materials' melting temperature. In this work, the spatio-temporal temperature field during FS is investigated within the substrate via a combined experimental-numerical approach. The study presents a robust and efficient thermal process model accounting for the contributions of friction and plasticity as heat input. The geometry of the applied heat source is dependent on the deposit geometry and the evolving flash. Extensive spatial temperature measurements for a dissimilar aluminum alloy combination are used in order to identify the required input parameters and to validate the model. The process temperature profiles for varied process parameters, such as axial force, rotational speed and travel speed as well as substrate thickness and backing plate material are systematically investigated, where experimental and numerical results are in good agreement. Deviations are in particular associated with possible experimental scatter and unknowns regarding the exact position of the measurement as well as modeling assumptions in terms of the heat source geometry. Overall, the detailed comparisons illustrate that the developed numerical model is able to obtain the temperature evolution and distribution during FS deposition with acceptable accuracy for a wide range of process conditions.
6 citations
TL;DR: In this paper, a review of microstructructural evaluation of different materials after the friction surfacing process is presented, where different parameters for this process are rotational speed, pressure or force applied, tilt angle and friction time.
4 citations
TL;DR: In this article , the authors used 3D X-ray computed tomography, electron backscatter diffraction, and transmission electron microscopy to reveal the mechanisms responsible for good bonding between the FRAM interlayers.
Abstract: Friction rolling additive manufacturing (FRAM) is an emerging solid-state additive manufacturing technology for high-strength aluminum alloys that are prone to produce solidification defects using fusion-based additive manufacturing method. However, the mechanisms responsible for good bonding between the FRAM interlayers remain unclear. This study successfully reveals such mechanisms for FRAM-produced hybrid AA2319 and AA6061 aluminum alloys using 3D X-ray computed tomography, electron backscatter diffraction, and transmission electron microscopy. Three findings concerning the quality of bonding between adjacent layers in FRAM were obtained. Firstly, material plastic flow and macroscopic migration behavior occurred simultaneously along the longitudinal and transverse directions at the interlayer, forming a macroscopic mechanically interlocking nonplanar interface. The convex thread at the tool head increased the material flow in the transverse direction, facilitating material mixing in the adjacent layer. Secondly, severe plastic deformation resulted in significant grain refinement on both sides of the interface. The average grain size reduction rates for the sides of AA2319 and AA6061 were 98.3% and 95.9%, respectively. Thirdly, direct contact with no obvious oxides resulted in complete metallurgical interface bonding. These findings can aid in the elucidation of the basic physical process of FRAM and provide guidance for process parameter optimization and tool head design in the future. • Mechanically interlocked non-planar interface was formed during the FRAM process. • Material flow occurred simultaneously along with the longitudinal and transverse directions at the interlayer. • Thread protrusion significantly increased the material flow in the transverse direction. • Severe plastic deformation resulted in significant grain size reduction for both sides of the interface. • It was experimentally proved that direct contact with no oxide was achieved at the interface, forming a complete metallurgical bonding.
4 citations
13 Jun 2021
TL;DR: In this article, a hybrid additive manufacturing (AM) process combining multilayer friction surfacing (FS) and metal machining operations is presented. But the feasibility of the process is tested using heat-treatable Aluminum alloy AA6061 rod on a mild steel substrate.
Abstract: This paper presents a hybrid additive manufacturing (AM) process combining multilayer friction surfacing (FS) and metal machining operations. While friction surfacing has been known as a part repair or coating process, we here present an attempt to use it to build whole 3D metallic parts. The feasibility of the process is tested using heat-treatable Aluminum alloy AA6061 rod on a mild steel substrate. A series of FS experiments was conducted with the purpose to identify suitable process settings. This included different combinations of rotational and travel speeds of the FS rod. Quality of deposited layers was assessed using different indicators including bond width, layer uniformity, layer thickness, and others. ANOVA was conducted to reveal the effects of process parameter settings on the quality metrics. Two metallic parts were printed successfully, which demonstrates the feasibility of the proposed hybrid process.
4 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