Friction Stir Deposition Method for Manufacturing an Article

Abstract

To provide a method for manufacturing an article comprising a step of depositing wear resistant material on a surface of a preform by laminated friction stir deposition.SOLUTION: A method comprises a step of depositing, by laminated friction stir deposition, wear-resistant material 410 on a surface 404 of a preform 400 in order to provide an intermediate article 420. The preform 400 comprises a first composition and the wear-resistant material 410 comprises a second composition. The second composition is substantially different from the first composition. The method also comprises a step of machining the intermediate article 420 in order to remove at least a portion of the wear-resistant material 410 from the intermediate article 420.SELECTED DRAWING: Figure 4A

Description

Technical Field

[0001] The present disclosure generally relates to additive manufacturing, and more specifically, to an additive friction stir deposition method for manufacturing an article.

Background Art

[0002] Articles created using additive manufacturing techniques are manufactured by adding material layer by layer. Friction stir additive manufacturing is a solid-state additive manufacturing technique based on friction stir welding. Additive friction stir deposition is a solid-state additive manufacturing technique that combines friction stir welding with a material supply and deposition process. In additive friction stir deposition, the feed material is delivered through a hollow friction stir tool. The friction stir tool rotates rapidly, generating heat by dynamic contact friction at the interface between the tool and the material. The heat is generated by dynamic contact friction between the friction stir tool and the material, dissipated by plastic deformation of the material, and transferred into the material by heat conduction. The heated and softened feed material is supplied through the friction stir tool and bonded to the substrate through plastic deformation at the interface. The additive friction stir deposition method can be used to manufacture articles for various applications.

[0003] Despite the progress already made, those skilled in the art in this field continue research and development efforts in the field of additive manufacturing, including applying the additive friction stir deposition method to manufacture different types of articles.

Summary of the Invention

Means for Solving the Problems

[0004] Disclosed is a method for manufacturing an article.

[0005] In one example, the disclosed method includes depositing a wear-resistant material on the surface of a preform by additive friction stir deposition to provide an intermediate article. The preform includes a first composition, and the wear-resistant material includes a second composition. The second composition is substantially different from the first composition. The method also includes machining the intermediate article to remove at least a portion of the wear-resistant material from the intermediate article.

[0006] In another example, the disclosed method is for manufacturing a gear including gear teeth from a preform containing a metallic material. The method includes the step of depositing a metal matrix composite material on the metallic material of the preform by laminated friction stir deposition in order to provide an intermediate article. The method also includes the step of machining the intermediate article to remove at least a portion of the metal matrix composite material deposited on the preform.

[0007] Parts such as gears are also disclosed.

[0008] In one example, the disclosed gear includes a gear core comprising a plurality of gear teeth protruding from the gear core. The gear also includes a wear-resistant layer disposed on at least a portion of each of the plurality of gear teeth. The gear further includes a mixed interface layer defined between the gear core and the wear-resistant layer disposed on the gear core.

[0009] Other examples of the disclosed methods and articles will be evident from the following detailed description, the accompanying drawings, and the accompanying claims. [Brief explanation of the drawing]

[0010] [Figure 1] This is a block diagram of an additive manufacturing system for depositing extruded material onto a substrate, as an example. [Figure 2] Figure 1 is a schematic perspective view of the subassembly of the additive manufacturing system. [Figure 3] Figure 1 is a schematic elevation cross-sectional view of the subassembly of the additive manufacturing system. [Figure 4A] This is a schematic elevation cross-sectional view of an exemplary article in the form of a gear, manufactured using the additive manufacturing system shown in Figure 1, as an example. [Figure 4B] This is another schematic elevation cross-sectional view of an exemplary article in the form of a gear, manufactured using the additive manufacturing system shown in Figure 1, as an example. [Figure 5A] This is a schematic elevation cross-sectional view of an exemplary article in the form of a gear, manufactured using the additive manufacturing system shown in Figure 1, as an example. [Figure 5B] This is another schematic elevation cross-sectional view of an exemplary article in the form of a gear, manufactured using the additive manufacturing system shown in Figure 1, as an example. [Figure 6A] This is a schematic elevation cross-sectional view of an exemplary article in the form of a gear, manufactured using the additive manufacturing system shown in Figure 1, as an example. [Figure 6B] This is another schematic elevation cross-sectional view of an exemplary article in the form of a gear, manufactured using the additive manufacturing system shown in Figure 1, as an example. [Figure 7] This is a block diagram illustrating an example of a method for depositing an extruded material onto a substrate to manufacture an article using the additive manufacturing system shown in Figure 1. [Figure 8] This is a block diagram illustrating an example of a method for depositing an extruded material onto a substrate to manufacture an article using the additive manufacturing system shown in Figure 1. [Figure 9] This is a block diagram of aircraft production and maintenance methods. [Figure 10] This is a schematic diagram of an aircraft. [Modes for carrying out the invention]

[0011] In this specification, “Example” means that one or more forms, structures, or characteristics described in relation to the Example are included in at least one implementation. The term “Example” in various parts of this specification may or may not refer to the same Example.

[0012] In FIG. 1 referred to above, if there are solid lines connecting various elements and / or components, they can represent mechanical, electrical, fluidic, optical, electromagnetic couplings and other couplings and / or combinations thereof. As used herein, "coupled" means related either directly or indirectly. For example, member A may be directly related to member B or, for example, indirectly related to member B via another member C. It will be understood that not all relationships between the various disclosed elements are necessarily represented. Thus, couplings other than those shown in the block diagram may exist. If there are dashed lines connecting the blocks designating various elements and / or components, they represent couplings similar to those indicated by the solid lines in terms of function and purpose. However, the couplings represented by the dashed lines may be provided optionally or may relate to alternative embodiments of the present disclosure. Similarly, if there are elements and / or components represented by dashed lines, they represent alternative examples of the present disclosure. One or more elements indicated by solid and / or dashed lines can be omitted from a particular example without departing from the scope of the present disclosure. If there are environmental elements, they are represented by dotted lines. For clarity, virtual (fictitious) elements can also be displayed. Those skilled in the art will understand that some of the forms shown in FIG. 1 need not include other forms described in FIG. 1, other drawings, and / or the accompanying disclosure and can be combined in various ways. Such combinations are not explicitly shown herein. Similarly, additional forms not limited to the examples presented may be combined with some or all of the forms shown and described herein.

[0013] In FIGS. 7, 8, and 9 referred to above, a block may represent an operation and / or a part thereof, and lines connecting various blocks do not imply a particular order or dependency of operations or parts thereof. Blocks represented by dashed lines represent alternative operations and / or parts thereof. If there are dashed lines connecting various blocks, it represents an alternative dependency of operations or parts thereof. It will be understood that not all dependencies between various disclosed operations are necessarily represented. The descriptions of FIGS. 7, 8, and 9, and the accompanying disclosure explaining the operations of the methods described herein, should not be construed as necessarily determining the sequence in which the operations are to be performed. Rather, while one exemplary order is shown, it should be understood that the sequence of operations may be changed when appropriate. Thus, certain operations may be performed in a different order or simultaneously. Further, those skilled in the art will understand that not all of the operations described need to be performed.

[0014] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the disclosed concepts, and these can be practiced without some or all of these details. In other instances, details of well-known devices and / or processes are omitted so as not to unnecessarily obscure the disclosure. Some concepts are described in relation to specific examples, but these examples are not intended to be limiting.

[0015] Unless otherwise indicated, terms such as "first", "second", etc. are used merely as labels and are not intended to impose requirements of order, position, or hierarchy on the items to which they refer. Further, a reference to, for example, a "second" item does not require or exclude the existence of, for example, a "first" or smaller numbered item, and / or a "third" or larger numbered item.

[0016] As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to perform” a particular function is not merely capable of performing that function after further modification, but can actually perform that function without modification. In other words, a system, apparatus, structure, article, element, component, or hardware “configured to perform” a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, “configured to” means an existing characteristic of the system, apparatus, structure, article, element, component, or hardware that enables it to perform a particular function without further modification. For the purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as “configured to perform” a particular function may additionally or alternatively be described as “adapted to” and / or “functioning to” perform that function.

[0017] For the purposes of this disclosure, the term “equivalent” means a state that is exactly identical to the described state, or substantially the same as the described state. Where used herein, the term “substantially” means a state that is similar to such an extent that it can be perceived as accurate. Thus, the phrase “A is equivalent to B” includes the condition that A is exactly the same as B, or A is within a given acceptable variance of B (e.g., + / - 5%), or vice versa.

[0018] Furthermore, as used herein, the term “approximately” refers to a state that is close to the described state but not exactly the same, such as a state that is within a predetermined acceptable tolerance or precision range, and still performs the desired function or achieves the desired result. For example, “approximately” refers to a state that is within 10% of the described state. However, the term “approximately” does not preclude a state that is identical to the described state.

[0019] As used herein, the term “extruded material” (e.g., extruded material 111) refers to material extruded through the agitation tool 118.

[0020] Exemplary and non-exclusive examples of the subject matter of this disclosure, whether claimed or not, are provided below.

[0021] Generally, referring to Figure 1, and especially to Figures 2 and 3, an additive manufacturing system 110 for depositing an extruded material 111 onto a substrate 114 is disclosed. The additive manufacturing system 110 includes a deposition head 116. The deposition head 116 includes a stirring tool 118. The stirring tool 118 has a rotating axis A R It is rotatable around the tool. As shown in Figure 3, the stirring tool 118 has a tool distal end 120 and a rotation axis A R The tool includes a proximal end 122 that axially opposes the distal end 120 of the tool. The tool shoulder 123 is formed on the distal end 120 of the stirring tool 118 and is positioned in physical (e.g., direct) contact with the surface of the preceding layer 112A of the substrate 114 or extruded 111. The stirring tool 118 defines a hole 124. The hole 124 extends from the proximal end 122 to the distal end 120. The hole 124 is configured to receive the raw material 126. The raw material 126 is biased toward the distal end 120 of the tool.

[0022] The additive manufacturing system 110 offers a wide range of functions, including additive manufacturing, coating application, component repair, metal joining, custom metal alloy and metal matrix composite billets, and part manufacturing by depositing layers 112A, 112B, and 112C of extruded material 111 onto a substrate 114.

[0023] The additive manufacturing system 110 is a solid-state process, meaning that the raw material 126 does not reach its melting temperature during the deposition process. In the additive friction stir deposition process using the additive manufacturing system 110, the raw material 126 is delivered through the holes 124 of the stir tool 118. The stir tool 118 rotates rapidly in the direction of the directional arrow 202, generating heat through dynamic contact friction at the interface between the tool and the material. The heat is generated by dynamic contact friction between the stir tool 118 and the build material. For the purposes of this disclosure, the term “build material” refers to at least one of the raw material 126, the extruded material 111, the substrate 114, or several combinations thereof. The heat is dissipated by the plastic deformation of the build material. The heat is transferred into the interior of the build material by thermal conduction and thermal convection through the flow of material. The heated and softened raw material 126 is supplied through the stir tool 118 as an extruded material 111 and bonds with the substrate 114 through plastic deformation at the interface.

[0024] As shown in Figure 2, for example, lateral movement of the agitator 118 in the direction of the directional arrow 200 results in the deposition of a single track or a single layer of extruded material 111. As best shown in Figure 3, the three-dimensional article 119 is produced by selectively adding subsequent layers 112A, 112B of extruded material 111 on top of preceding layers 112B, 112C of extruded material 111 (for example, the three layers 112A, 112B, and 112C of extruded material 111 are shown in Figures 2 and 3).

[0025] In one or more examples, the tool distal end 120 of the stirring tool 118 includes or forms a tool shoulder 123 which is positioned in physical (e.g., direct) contact with the surface of the substrate 114 (e.g., during the deposition of the initial layer 112C of the extruded 111) or with the preceding layers 112A, 112B, 112C of the extruded 111 (e.g., during the deposition of the subsequent layer 112A or 112B of the extruded 111). The hole 124 extends through the tool shoulder 123 formed at the distal end 120 of the stirring tool 118, and the raw material 126 is biased toward the distal end 120 of the tool and positioned in physical (e.g., direct) contact with the substrate 114 (e.g., during the deposition of the initial layer 112C of the extruded 111) or (e.g., during the deposition of the subsequent layer 112A or 112B of the extruded 111) the preceding layers 112A, 112B, 112C of the extruded 111. The dynamic contact friction between the tool shoulder 123 formed at the distal end 120 of the stirring tool 118 and the substrate 114 or the preceding layers 112A, 112B, 112C of the extruded 111 generates heat during the rotation of the stirring tool 118. The dynamic contact friction between the raw material 126 and the preceding layers 112A, 112B, and 112C of the substrate 114 or extruded 111 generates heat during the rotation of the raw material 126, which rotates in conjunction with the rotation of the stirring tool 118.

[0026] The rapid rotation of the agitator 118 generates heat through dynamic contact friction between the agitator 118 and the substrate 114 (for example, during the deposition of the initial layer 112C of the extruded material 111) or between the agitator 118 and the preceding layers 112A, 112B, and 112C of the extruded material 111 (for example, during the deposition of the subsequent layers 112A and 112B of the extruded material 111).

[0027] Generally, referring to Figure 1, and especially to Figures 2 and 3, the raw material 126 is received in the hole 124 such that the rotation of the stirring tool 118 causes the corresponding rotation of the raw material 126. The rotation of the stirring tool 118 also causes rotation axis A RThe raw material 126 located in the hole 124 of the agitator tool 118 is rotated (e.g., co-rotated) around the agitator. The rapid rotation of the raw material 126 generates heat through dynamic contact friction between the raw material 126 and the substrate 114 (e.g., during the deposition of the initial layer 112C of the extruded material 111) or between the raw material 126 and the preceding layers 112A, 112B, 112C of the extruded material 111 (e.g., during the deposition of the subsequent layers 112A, 112B of the extruded material 111).

[0028] In one or more examples, the raw material 126 is biased toward the distal end 120 of the stirring tool 118 and comes into contact with the substrate 114 (e.g., during the deposition of the initial layer 112C of the extruded 111) or the preceding layers 112A, 112B, 112C of the extruded 111 (e.g., during the deposition of the subsequent layers 112A, 112B of the extruded 111) by a raw material force sufficient to inhibit the rotation of the raw material 126 relative to the stirring tool 118.

[0029] Generally, referring to Figure 1, the raw material 126 includes a metal or a metal alloy. The raw material 126, which is a metal or a metal alloy, enables the additive manufacturing system 110 to produce a three-dimensional article 119 formed from any one of various custom metals or metal alloys by depositing an extruded material 111 onto a substrate 114.

[0030] In one or more examples, metals include any one or more of a broad range of metals, including but not limited to steel, aluminum, nickel, copper, magnesium, titanium, and iron. In one or more examples, metal alloys include any one or more of a broad range of metal alloys formed from iron, carbon, steel, manganese, nickel, chromium, molybdenum, boron, titanium, vanadium, tungsten, cobalt, niobium, or combinations thereof.

[0031] In one or more examples, all layers 112A, 112B, 112C of the extruded material 111 deposited on the substrate 114 are formed from the same raw material (e.g., the same metal or metal alloy). In such examples, the three-dimensional article 119 formed by the deposition process using the additive manufacturing system 110 is homogeneous. In one or more examples, at least one layer 112A, 112B, 112C of the extruded material 111 deposited on the substrate 114 is formed from a different raw material than at least one other layer 112A, 112B, 112C of the extruded material 111 deposited on the substrate 114. In such examples, the three-dimensional article 119 formed by the deposition process using the additive manufacturing system 110 is heterogeneous. Heterogeneous composition allows for macroscopic anisotropic behavior and / or anisotropic behavior of components with properties tailored to the desired location. For example, a layer with high thermal conductivity can be added to preferentially and effectively dissipate heat in one direction.

[0032] In one or more examples, raw material 126 is a solid material such as a solid rod of metal or a solid rod of metal alloy. In one or more examples, raw material 126 is a powder material such as powdered metal or powdered metal alloy.

[0033] A descriptive example of a three-dimensional article 119 formed from layers 112A, 112B, 112C of extruded material 111 deposited on a substrate 114 is a three-dimensional article 119 formed from substantially linear layers 112A, 112B, 112C of extruded material 111 in a plan view, but in other examples, one or more layers 112A, 112B, 112C of the three-dimensional article 119 or extruded material 111 have a nonlinear or complex shape in a plan view. In one or more examples, it should be understood that the movement path of the deposition head 116 for the deposition of any given layer 112A, 112B, 112C of extruded material 111 depends on various factors such as the shape of a portion of the three-dimensional article 119 formed by each layer of extruded material 111.

[0034] As shown in Figures 2 and 3, in one or more examples, each layer 112A, 112B, 112C of the extruded material 111 is deposited by moving the depositing head 116 along a substantially linear migration path, thereby forming a linear layer of the extruded material 111.

[0035] In one or more examples, one or more layers 112A, 112B, 112C of the extruded material 111 are deposited by moving the deposition head 116 along a nonlinear movement path, thereby forming the nonlinear layers 112A, 112B, 112C of the extruded material 111. Linear or nonlinear motion may need to have different geographical orientations. For example, linear motion can be used in the manufacture of gears with teeth in the longitudinal direction, while nonlinear motion may be required to manufacture screw actuators.

[0036] Referring generally to Figure 1, the additive manufacturing system 110 further includes several control devices 140, including a control unit 142 and an agitation tool force applicator 144 configured to press the deposition head 116 against the substrate 114. The agitation tool force applicator 144 allows for selective control of the position of the agitation tool 118 relative to the substrate 114 or to the preceding layers 112A, 112B, 112C during the deposition of the extruded material 111.

[0037] The agitation tool force applicator 144 may be any one of various types of force application devices, linear motion control devices, or actuators suitable for selectively applying agitation tool force. The agitation tool 118 generates two types of forces: one is essentially rotational friction that generates heat, and the other is a pressure on the working part and a translational force that moves the tool through the components, the balance of which forces depends on the configuration and parameters of the deposit. As used herein, agitation tool force includes torque and vertical load applied by the tool. The agitation tool force is selectively applied to the agitation tool 118, and the agitation tool 118 rotates on axis A RThe stirring tool force applicator 144 is selectively positioned against the substrate 114 or against the preceding layers 112A, 112B, 112C of the extruded material 111, such as along the edges. In one or more examples, the stirring tool force applicator 144 is operably coupled to the stirring tool 118. The stirring tool force applicator 144 is configured to press the stirring tool 118 against the substrate 114 or the preceding layers 112A, 112B, 112C of the extruded material 111, so that the tool shoulder 123 of the tool distal end 120 makes direct physical contact with the substrate 114 or the preceding layers 112A, 112B, 112C of the extruded material 111 with a force sufficient to generate heat through dynamic contact friction as the stirring tool 118 rotates.

[0038] In one or more examples, the agitation tool force applicator 144 is a linear actuator. In one or more examples, the agitation tool force applicator 144 includes at least one of a pneumatic linear actuator, a hydraulic linear actuator, or a mechanical linear actuator. The use of at least one of a pneumatic linear actuator, a hydraulic linear actuator, or a mechanical linear actuator as the agitation tool force applicator 144 provides a simple, effective, and repeatable means of selectively positioning the agitation tool 118 relative to the substrate 114.

[0039] In one or more examples, the control unit 142 is communicatively coupled to the agitation tool force applicator 144. The control unit 142 is configured to provide operating instructions to the agitation tool force applicator 144 in order to selectively position the agitation tool 118 during the deposition of the extruded material 111.

[0040] Generally, referring to Figure 1, the control device 140 rotates the stirring tool 118 on axis A while the stirring tool force applicator 144 presses the deposition head 116 against the substrate 114. R The device further includes a stirring tool rotating device 146 configured to rotate around the shaft A during the deposition of the extruded material 111. R This allows for rapid rotation of the stirring tool 118 around it.

[0041] The stirring tool rotating device 146 has a rotating shaft A R The stirring tool 118 can be rotated by any of the following types of rotational force application devices, rotational motion control devices, or actuators suitable for rotating the stirring tool 118 around the substrate 114. In one or more examples, the stirring tool rotator 146 is operably coupled to the stirring tool 118. With the tool shoulder 123 of the tool distal end 120 of the stirring tool 118 in contact with the substrate 114 (e.g., during the deposition of the initial layer 112C of the extruded 111) or the preceding layers 112A, 112B, 112C of the extruded 111 (e.g., during the deposition of the subsequent layers 112A, 112B of the extruded 111), the stirring tool rotator 146 is configured to rotate the stirring tool 118 at a rotational speed sufficient to generate heat by dynamic contact friction at the deposition interface.

[0042] In one or more examples, the agitation tool rotating device 146 is a rotary actuator. In one or more examples, the agitation tool rotating device 146 includes at least one of a pneumatic rotary actuator, a hydraulic rotary actuator, or a mechanical rotary actuator. Using at least one of a pneumatic rotary actuator, a hydraulic rotary actuator, or a mechanical rotary actuator as the agitation tool rotating device 146 provides a simple, effective, and repeatable means for rapidly rotating the agitation tool 118.

[0043] In one or more examples, the control unit 142 is communicatively coupled to the agitation tool rotating device 146. The control unit 142 is configured to provide the agitation tool rotating device 146 with operating instructions to rotate the agitation tool 118 while the extruded material 111 is being deposited.

[0044] Generally referring to Figure 1, the control device 140 further includes a material force applicator 148 that biases the material 126 toward the distal end 120 of the tool. The material force applicator 148 facilitates the material 126 to come into contact with the substrate 114 or the preceding layers 112A, 112B, 112C of the extruded material 111 during deposition.

[0045] The raw material force applicator 148 selectively applies the raw material force to the raw material 126, and rotates the shaft A R The force applicator may be one of various types of force application devices, linear motion control devices, or actuators suitable for positioning the raw material 126 to contact the preceding layers 112A, 112B, 112C of the substrate 114 or the extruded material 111, such as along a curve. In one or more examples, the raw material force applicator 148 is operably coupled to the raw material 126. The raw material force applicator 148 is configured to press the raw material 126 against the substrate 114 (or the preceding layers 112A, 112B, 112C of the extruded material 111), so that when the raw material 126 rotates (for example, when the raw material 126 rotates with the stirring tool 118), the raw material 126 positioned at the distal end 120 of the stirring tool 118, or protruding from the distal end 120 of the stirring tool, comes into direct physical contact with the substrate 114 (or the preceding layers 112A, 112B, 112C of the extruded material 111) with a force sufficient to generate heat through dynamic contact friction.

[0046] In one or more examples, the raw material force applicator 148 is a linear actuator. In one or more examples, the raw material force applicator 148 includes at least one of a pneumatic linear actuator, a hydraulic linear actuator, or a mechanical linear actuator. Using at least one of a pneumatic linear actuator, a hydraulic linear actuator, or a mechanical linear actuator as the raw material force applicator 148 provides a simple, effective, and reproducible means of selectively prompting the raw material 126 to come into contact with the substrate 114 (or the preceding layers 112A, 112B, 112C of the extruded material 111).

[0047] In one or more examples, the control unit 142 is communicatively coupled to the raw material force applicator 148. The control unit 142 is configured to provide the raw material force applicator 148 with operational instructions to propel the raw material 126 toward the distal end 120 of the agitation tool 118 (for example, outward from the hole 124) during the deposition of the extruded material 111.

[0048] Generally referring to Figure 1, the additive manufacturing system 110 further includes a carriage 150 connected to the deposition head 116. The carriage 150 moves the deposition head 116 relative to the substrate 114. The carriage 150 allows the deposition head 116 to move relative to the substrate 114 (or the preceding layers 112A, 112B, 112C of the extruded material 111) independently of the substrate 114 during the deposition of subsequent layers 112A, 112B, 112C of the extruded material 111.

[0049] The carriage 150 can be any one or various types of motion control devices or tool manipulators. In one or more examples, the carriage 150 is a programmable robotic manipulator, such as a robotic arm, configured to automatically move the stacking head 116 in three-dimensional space. In such examples, the stacking head 116 takes the form of an end effector connected to the working end of the robotic arm.

[0050] In one or more examples, the control unit 142 is communicatively coupled to the carriage 150. The control unit 142 is configured to provide the carriage 150 with operational instructions for selectively positioning and moving the loading head 116 during the loading of the extruded material 111.

[0051] In one or more examples, additionally or alternatively, the additive manufacturing system 110 also includes a second carriage 250 connected to the substrate 114. The second carriage 250 moves the substrate 114 relative to the deposition head 116. The second carriage 250 allows the substrate 114 to move relative to the deposition head 116 independently of the deposition head 116 during the deposition of subsequent layers 112A, 112B, 112C of the extruded material 111. The second carriage 250 may be any one or various types of motion control device or tool manipulator. In one or more examples, the second carriage 250 is a programmable robotic manipulator, such as a robotic arm, configured to automatically move the substrate 114 in three-dimensional space. In one or more examples, a control unit 142 is communicatively coupled to the second carriage 250. The control unit 142 is configured to provide the second carriage 250 with operational instructions for selectively positioning and moving the loading head 116 during the loading of the extruded material 111.

[0052] Referring generally to Figures 4A and 4B, a general and non-limiting example of an article 119 that can be manufactured using the additive manufacturing system 110 is an aircraft component 460. A specific non-limiting example of an aircraft component 460 that can be manufactured using the additive manufacturing system 110 is a gear 430 having gear teeth 432.

[0053] As shown in Figure 4A, a preform 400 having the exemplary shape shown in Figure 4A is provided (for example, machined from a blank). The preform 400 comprises a high-toughness material and has a longitudinal central axis 402.

[0054] In some examples, the high-toughness material of preform 400 may include steel, aluminum, titanium alloys, or titanium in which boron particles are diffused. An example composition of preform 400 (i.e., the first composition) is Ti-6Al-4V.

[0055] The extruded material 111 is applied to the outer surface 404 of the preform 400 using the additive manufacturing system 110 shown in Figure 1 to form an intermediate article 420. The preform 400 comprises a first composition. The extruded material 111 comprises a wear-resistant material 410 (i.e., a second composition which may differ from the first composition). The wear-resistant material 410 may include a gamma alloy, an aluminum material metal matrix composite, an aluminum alloy, or an aluminum alloy having alumina with silicon carbide spherical particles for wear resistance. In some examples, the wear-resistant material 410 may include a metal matrix composite, the composition of which may be graded to achieve better overall performance.

[0056] Intermediate article 420 is machined to remove portion 438 of the wear-resistant material 410 to form a gear 430, which includes a gear core 431 and a plurality of gear teeth 432 protruding from the gear core 431. A wear-resistant layer 440 is disposed on at least a portion 446 of each of the plurality of gear teeth 432. A mixed interface layer 450 is defined between the gear core 431 and the wear-resistant layer 440 disposed on the gear core 431. The mixed interface layer 450 provides a bond between the wear-resistant material 410 and the gear core 431. Portion 448 of the gear core 431 and the wear-resistant material 410 are plasticized to produce the mixed interface layer 450. In some examples, the mixed interface layer 450 includes a refined particulate microstructure sized substantially at the nanometer and micrometer levels. This includes nanoparticles (<100 nm), ultrafine particles or UFG (100 nm to 500 nm), and microparticles (>0.5 μm).

[0057] As shown in Figure 4B, multiple manufactured gears 435 can be manufactured from a rod-shaped structure 436, which can be cut like a slice of bread along the longitudinal central axis 402 of a preform 400 to provide multiple manufactured gears 435, such as individual gears 430a, 430b, 430c, 430d, etc.

[0058] Referring generally to Figures 5A and 5B, another example of an article 119 that can be manufactured using the additive manufacturing system 110 is another aircraft component 534. The aircraft component 534 is in the form of a gear having gear teeth 532.

[0059] As shown in Figure 5A, a preform 500 having a circumferential surface 562 is provided. In some examples, an extruded material 564, which may be a metallic material, is first deposited on a metallic substrate 563 on the circumferential surface 562 of a cylindrical body 560 by laminated friction stir deposition to produce a first intermediate article 510. In some examples, the metallic material 564 and the metallic substrate 563 are substantially the same in composition. The preform 500 may contain a high-toughness material and may define a longitudinal central axis 502.

[0060] In some examples, the high-toughness material for preform 500 can be steel, aluminum, titanium alloys, or titanium with boron particles diffused on it. An example composition of preform 500 is Ti-6Al-4V. In another example, Ti5321 is used in alpha-beta thermomechanical heat treatment. In yet another example, high-toughness aluminum alloys such as Al7475-T7351 can be used.

[0061] Next, an additional extruded material 111 (e.g., wear-resistant material 506) is applied to the outer surface 504 of the preform 500 using the additive manufacturing system 110 of Figure 1 to form a second intermediate article 520. It should be clear that the deposition of the metal material 564 onto the metal substrate 563 of the circumferential surface 562 of the cylindrical body 560 by additive friction stir deposition for producing the preform 500 precedes the deposition of the wear-resistant material 506 onto the preform 500 by additive friction stir deposition. In this example, the additional extruded material 111 includes the wear-resistant material 506. The wear-resistant material 506 may include a gamma alloy, an aluminum material metal matrix composite, an aluminum alloy, or an aluminum alloy having alumina with silicon carbide spherical particles for wear resistance. In some examples, the wear-resistant material 506 may include a metal matrix composite, the composition of which may be graded to achieve better overall performance. In this case, preform 500 may be a material exhibiting high toughness, and materials with a higher ceramic content will be closer to the wear surface due to improved wear resistance through increased hardness.

[0062] The intermediate article 520 is machined to remove a portion 538 of the wear-resistant material 506 from the intermediate article 520 to form a gear 530 having a gear core 531 (i.e., a cylindrical body 560) and a plurality of gear teeth 532 protruding from the gear core 531. The wear-resistant layer 540 is disposed on at least a portion 536 of each of the plurality of gear teeth 532. A mixed interface layer 550 is defined between the gear core 531 and the wear-resistant layer 540 disposed on the gear core 531. A portion 508 of the preform 500 and the wear-resistant material 506 are plasticized to produce the mixed interface layer 550. In some examples, the mixed interface layer 550 includes refined particulate microstructures sized substantially at the nanometer and micrometer levels. These include nanoparticles (<100 nm), ultrafine particles or UFGs (100 nm to 500 nm), and microparticles (>0.5 μm).

[0063] As shown in Figure 5B, multiple gears 535 can be manufactured from a rod-shaped structure 537, where individual gears 530a, 530b, 530c, 530d, etc., can be cut like slices of bread along the longitudinal central axis 502 of a preform 500 for forming multiple manufactured gears 535.

[0064] Referring generally to Figures 6A and 6B, another example of an article 119 manufactured using the additive manufacturing system 110 is another aircraft component 634, specifically a gear 630 having gear teeth 632.

[0065] As shown in Figure 6A, the preform 600 includes a body portion 601 and partially formed gear teeth 603 protruding from the body portion 601. The preform 600 may be formed from a high-toughness material and may define a longitudinal central axis 602. In some examples, the high-toughness material of the preform 600 may be steel, aluminum, titanium alloy, or a high-toughness alloy such as titanium in which boron particles are diffused. An example composition of the preform 600 is Ti-6Al-4V.

[0066] The extruded material 111 is applied to the outer surface 604 of the preform 600 using the additive manufacturing system 110 of Figure 1 to form an intermediate article 620. The extruded material is (or contains) a wear-resistant material 610. The wear-resistant material 610 may include a gamma alloy, an aluminum material metal matrix composite, an aluminum alloy, or an aluminum alloy having alumina with silicon carbide spherical particles for wear resistance. In some examples, the wear-resistant material 610 may include a metal matrix composite, the composition of which may be graded to achieve better overall performance. For example, the preform 600 may be a material exhibiting high toughness, and the wear-resistant material 610 may have a higher ceramic content and may be placed near the wear surface to improve wear resistance by increasing hardness. It should be obvious that the wear-resistant material 610 is deposited on the partially formed gear teeth 603 of the preform 600.

[0067] Intermediate article 620 is machined to form a gear 630, which includes a gear core 631 (i.e., body portion 601) and a plurality of gear teeth 632 protruding from the gear core 631, by removing portion 638 of the wear-resistant material 610. A wear-resistant layer 640 is disposed on at least a portion 636 of each of the plurality of gear teeth 632. A mixed interface layer 650 is defined between the gear core 631 and the wear-resistant layer 640 disposed on the gear core 631. Portion 608 of the gear core 631 and the wear-resistant material 610 are plasticized to produce the mixed interface layer 650. In some examples, the mixed interface layer 650 includes a refined particulate microstructure sized substantially at the nanometer and micrometer levels. This includes nanoparticles (<100 nm), ultrafine particles or UFGs (100 nm to 500 nm), and microparticles (>0.5 μm).

[0068] As shown in Figure 6B, multiple gears 642 can be manufactured from a rod-shaped structure 644, where individual gears 630a, 630b, 630c, 630d, etc., can be cut like slices of bread along the longitudinal central axis 602 of a preform 600 to provide multiple manufactured gears 642.

[0069] Generally referring to Figure 7, and especially to Figures 1 and 3, a method 700 is disclosed for manufacturing an article 119 by depositing an extruded material 111 onto a substrate 114. Method 700 includes the step of providing a preform (block 702). Method 700 also includes the step of depositing a wear-resistant material onto the surface of the preform by laminated friction stir deposition to form an intermediate article (block 704). The preform comprises a first composition, and the wear-resistant material comprises a second composition which may differ from the first composition. For example, the second composition may be significantly functionally different from the first composition. Method 700 further includes the step of machining the intermediate article to remove at least a portion of the wear-resistant material from the intermediate article (block 706). The result is an article manufactured by Method 700 in Figure 7. The manufactured article may be lighter for a given power / load capacity, have better wear and tear resistance, and have better corrosion resistance.

[0070] In some examples, the first composition includes at least one of aluminum alloys, titanium alloys, and steel.

[0071] In some examples, the first composition contains Ti-6Al-4V.

[0072] In some examples, the wear-resistant material includes a metal matrix composite. In some examples, the metal matrix composite includes a selection of aluminum alloys containing alumina particles, aluminum alloys containing titanium diboride particles, and aluminum matrices containing ceramic reinforcements.

[0073] In some examples, the step of depositing wear-resistant material by laminated friction stir deposition includes the step of depositing a substantially uniform wear-resistant material on the surface of a preform.

[0074] In some examples, the step of depositing wear-resistant material by layered friction stir deposition includes the step of depositing wear-resistant material in stages on the surface of a preform.

[0075] In some examples, the step of depositing a stepwise wear-resistant material includes the steps of depositing a first wear-resistant material on the surface of a preform and depositing a second wear-resistant material on top of the first wear-resistant material.

[0076] In some cases, a starting material (e.g., a blank) is machined to produce a preform.

[0077] In some examples, the preform includes partially formed gear teeth, and the wear-resistant material is deposited on the partially formed gear teeth.

[0078] In some examples, the preform includes a nearly cylindrical body, and the surface is the circumferential surface of the nearly cylindrical body.

[0079] In some examples, the preform is in the form of a gear with gear teeth, and the wear-resistant material forms a protective coating layer on the gear teeth.

[0080] In some examples, this method further includes the step of depositing a metallic material on a metal substrate to generate a preform, prior to the step of depositing a wear-resistant material by multilayer friction stir deposition. In some examples, the metallic material and the metal substrate are substantially identical in composition.

[0081] In some examples, the step of depositing the wear-resistant material by stacked friction stir deposition includes the step of plasticizing portions of the preform and wear-resistant material to create a mixed interface layer between the preform and the wear-resistant material. In some examples, the mixed interface layer comprises refined particulate microstructures sized substantially at the nanometer and micrometer levels. These include nanoparticles (<100 nm), ultrafine particles or UFGs (100 nm to 500 nm), and microparticles (>0.5 μm).

[0082] In some examples, aircraft components are manufactured according to method 700 shown in Figure 7.

[0083] In some cases, the gears are manufactured according to method 700 shown in Figure 7.

[0084] Generally, referring to Figure 8, and especially to Figures 1 and 3, a method 800 is disclosed for depositing an extruded 111 onto a substrate 114 to manufacture a gear containing gear teeth from a preform containing a metallic material. Method 800 includes the step of depositing a metal matrix composite material onto the metallic material of the preform by laminated friction stir deposition to form an intermediate article (block 802). Method 800 also includes the step of machining the intermediate article to remove at least a portion of the metal matrix composite material deposited on the preform (block 804). As a result, a gear containing gear teeth manufactured by Method 800 in Figure 8 is obtained. The manufactured gear is lightweight for a given power / load capacity, has excellent wear resistance and tear resistance, and also has excellent corrosion resistance.

[0085] In some cases, the metal matrix composite material that remains after the steps of depositing it onto the preform and machining it forms a wear-resistant protective coating layer on the gear teeth.

[0086] In some examples, the metallic material includes at least one of aluminum alloys, titanium alloys, and steel.

[0087] In some examples, the metal matrix composite material includes a selection of aluminum alloys containing alumina particles, aluminum alloys containing titanium diboride particles, and aluminum matrices containing ceramic reinforcements.

[0088] In some examples, the step of depositing a metal matrix composite by stacked friction stir deposition includes the step of plasticizing portions of the preform and the metal matrix composite to create a mixed interface layer between the preform and the metal matrix composite.

[0089] In some examples, the machining step produces a machined intermediate article, and the method further includes the step of cutting the machined intermediate article across the longitudinal central axis of the preform to form multiple manufactured gears.

[0090] Examples of this disclosure can be described in relation to an aircraft manufacturing and maintenance method 1100 as shown in Figure 9 and an aircraft 1102 as shown in Figure 10. Before production, the exemplary method 1100 may include the specification and design of the aircraft 1102 (block 1104) and material procurement (block 1106). During production, the manufacturing of components and subassemblies of the aircraft 1102 (block 1108) and system integration (block 1110) may be carried out. Subsequently, the aircraft 1102 may undergo certification and transport (block 1112) and enter service (block 1114). While in service, the aircraft 1102 may be scheduled for periodic maintenance and inspection (block 1116). Periodic maintenance and inspection may include the modification, reconfiguration, or refurbishment of one or more systems of the aircraft 1102.

[0091] Each process of the exemplary method 1100 may be performed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, the system integrator may, in no way, include any number of aircraft manufacturers and subcontractors of key systems; the third party may, in no way, include any number of vendors, subcontractors, and suppliers; and the operator may be an airline, leasing company, military, service organization, etc.

[0092] As shown in Figure 10, an aircraft 1102 manufactured by the exemplary method 1100 may include a fuselage 1118 and interior 1122 having a plurality of high-level systems 1120. Examples of high-level systems 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may also be applied to other industries such as the automotive industry. Thus, in addition to aircraft 1102, the principles disclosed herein may also be applied to other vehicles such as land vehicles, sea vehicles, and space vehicles.

[0093] The apparatus and methods shown or described herein may be used during any one or more stages of the manufacturing and maintenance method 1100. For example, components or subassemblies corresponding to the manufacture of components and subassemblies (block 1108) may be manufactured in the same manner as components or subassemblies produced while the aircraft 1102 is in service (block 1114). Also, one or more examples of apparatus, methods, or combinations thereof may be used during the manufacturing stages (blocks 1108 and 1110) for example, to substantially expedite the assembly of the aircraft 1102 or to reduce manufacturing costs. Similarly, one or more examples of the implementation of apparatus or methods, or combinations thereof, may be used, for example, without limitation, while the aircraft 1102 is in service (block 1114) and / or during maintenance and inspection (block 1116).

[0094] Different examples of the apparatus and methods disclosed herein include a variety of components, forms, and functions. It should be understood that various examples of the apparatus and methods disclosed herein may, in any combination, include any of the components, forms, and functions of any other examples of the apparatus and methods disclosed herein, and all such possibilities are intended to be included within the scope of this disclosure.

[0095] Many modifications of the examples described herein can be conceived by those skilled in the art, and this disclosure relates thereto in the interest of the teachings presented in the foregoing description and the related drawings.

[0096] Furthermore, this disclosure includes embodiments relating to the following clauses:

[0097] Clause 1. A method for manufacturing an article, the method is: To provide an intermediate article, the process involves depositing a wear-resistant material onto the surface of a preform by laminated friction stir deposition, The steps include machining the intermediate article in order to remove at least a portion of the wear-resistant material from the intermediate article, and Methods that include...

[0098] Clause 2. The method according to Clause 1, wherein the preform comprises a first composition and the wear-resistant material comprises a second composition, the second composition being substantially different from the first composition.

[0099] Clause 3. The method according to Clause 2, wherein the first composition comprises at least one of aluminum alloys, titanium alloys, and steel.

[0100] Clause 4. The method according to Clause 2, wherein the first composition comprises Ti-6Al-4V.

[0101] Clause 5. The method according to Clause 1, wherein the wear-resistant material includes a metal matrix composite material.

[0102] Clause 6. The method according to Clause 5, wherein the metal matrix composite material includes a selected aluminum alloy containing alumina particles, an aluminum alloy containing titanium diboride particles, and an aluminum matrix containing ceramic reinforcement.

[0103] Clause 7. The method according to Clause 1, wherein the step of depositing wear-resistant material by laminated friction stir deposition includes the step of depositing a substantially uniform wear-resistant material on the surface of a preform.

[0104] Clause 8. The method according to Clause 1, wherein the step of depositing wear-resistant material by laminated friction stir deposition includes the step of depositing wear-resistant material in stages on the surface of a preform.

[0105] Clause 9. The step of depositing a stepwise wear-resistant material, A step of depositing a first wear-resistant material onto the surface of the preform, The steps include: depositing a second wear-resistant material on top of a first wear-resistant material; The method described in Article 8, including the method described in Article 8.

[0106] Clause 10. The method according to Clause 1, further comprising the step of machining the starting material to produce a preform.

[0107] Clause 11. The method according to Clause 1, wherein the preform includes partially formed gear teeth, and a wear-resistant material is deposited on the partially formed gear teeth.

[0108] Clause 12. The method according to Clause 1, wherein the preform comprises a substantially cylindrical body, and the surface is the circumferential surface of the substantially cylindrical body.

[0109] Clause 13. The method according to Clause 1, wherein the preform is in the form of a gear having gear teeth, and a wear-resistant material forms a protective coating layer on the gear teeth.

[0110] Clause 14. The method according to Clause 1, further comprising the step of depositing a metallic material on a metal substrate by laminated friction stir deposition to produce a preform, prior to the step of depositing a wear-resistant material by laminated friction stir deposition.

[0111] Clause 15. The method according to Clause 14, wherein the metallic material and the metallic substrate are substantially the same in composition.

[0112] Clause 16. The method according to Clause 1, wherein the step of depositing a wear-resistant material by laminated friction stir deposition includes the step of plasticizing portions of the preform and the wear-resistant material to create a mixed interface layer between the preform and the wear-resistant material.

[0113] Clause 17. The method according to Clause 16, wherein the mixed interface layer comprises a purified particulate microstructure.

[0114] Clause 18. Aircraft components manufactured in accordance with the method described in Clause 1.

[0115] Clause 19. Gears manufactured in accordance with the method described in Clause 1.

[0116] Clause 20. A method for manufacturing a gear having gear teeth from a preform containing a metallic material, the method being: To provide an intermediate article, the steps include depositing a metal matrix composite material onto a metal material of a preform by laminated friction stir deposition, The steps include machining an intermediate article to remove at least a portion of the metal matrix composite material deposited on the preform, and Methods that include...

[0117] Clause 21. The method according to Clause 20, wherein the metal matrix composite material deposited on the preform and remaining after the machining step forms a wear-resistant protective coating layer on the gear teeth.

[0118] Clause 22. The method according to Clause 20, wherein the metallic material includes at least one of aluminum alloys, titanium alloys, and steel.

[0119] Clause 23. The method according to Clause 20, wherein the metal matrix composite material includes a selected aluminum alloy containing alumina particles, an aluminum alloy containing titanium diboride particles, and an aluminum matrix containing ceramic reinforcement.

[0120] Clause 24. The method according to Clause 20, wherein the step of depositing a metal matrix composite by laminated friction stir deposition includes the step of plasticizing portions of the preform and the metal matrix composite to generate a mixed interface layer between the preform and the metal matrix composite.

[0121] Clause 25. The machining step produces a machined intermediate article, and the method is: Steps to provide multiple manufactured gears: Cutting machined intermediate pieces across the longitudinal central axis of the preform. The method described in Clause 20, further including the method described in Clause 20.

[0122] Clause 26. A gear core comprising a plurality of gear teeth protruding from the gear core, A wear-resistant layer is provided on at least a portion of each gear tooth of a plurality of gear teeth, A defined mixed interface layer between the gear core and the wear-resistant layer placed on the gear core and A gear equipped with a gear.

[0123] Clause 27. The gear core includes a metallic material selected from aluminum alloy, titanium alloy, and steel. The wear-resistant layer includes a metal matrix composite material. The gears described in Article 26.

[0124] Clause 28. The gear according to Clause 26, wherein the mixed interface layer comprises a refined particulate microstructure.

[0125] Thus, it should be understood that this disclosure is not limited to the specific examples illustrated, and modifications and other examples are intended to be included within the scope of the appended claims. Furthermore, while the foregoing description and associated drawings illustrate examples of this disclosure in relation to specific exemplary combinations of elements and / or functions, different combinations of elements and / or functions may be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, the reference numerals in parentheses within the appended claims are presented for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided in this disclosure. [Explanation of Symbols]

[0126] 110 Additive Manufacturing System 111 Extruded 112A layer 112B layer 112C layer 114 circuit boards 116 Deposit head 118 Mixing Tools 119 Three-dimensional objects 120 Tool distal end 122 Tool proximal end 123 Tool Shoulder 124 holes 126 Raw materials 140 Control device 142 Control Unit 144 Mixing Tool Applicator 146. Rotating stirring tool device 148 Raw Material Power Applicator 150 Carriage 200 Directional Arrows 202 Directional Arrow 250 Second carriage 400 preforms 402 Longitudinal central axis 404 Exterior 410 Abrasion-resistant material 420 Intermediate items 430 gears 430a Gear 430b Gear 430c gear 430d gear 431 Gear Core 432 gear teeth 435 Gear 436 Rod structure 438 parts 440 Wear resistant layer 446 part 448 parts 450 Mixed interface layer 460 Aircraft Components 500 preforms 502 Longitudinal central axis 504 Exterior 506 Abrasion-resistant material 508 parts 510 First Intermediate Article 520 Second Intermediate Article 530 Gears 530a Gear 530b Gear 530c gear 530d gear 531 Gear Core 532 gear teeth 534 Aircraft Components 535 Gear 536 part 537 Rod-shaped structure 538 parts 540 Wear resistant layer 550 Mixed interface layer 560 Cylindrical body 562 Peripheral surface 563 Metal substrate 564 Metal materials 600 Preform 601 Main body part 602 Longitudinal central axis 603 Gear teeth 604 Exterior 610 Abrasion-resistant material 620 Intermediate items 630 Gears 630a Gear 630b Gear 630c gear 630d gear 631 Gear Core 632 gear teeth 634 Aircraft Components 636 part 638 parts 640 Wear resistant layer 642 Gears 644 Rod structure 650 Mixed interface layer 1100 Maintenance and Inspection Methods 1102 Aircraft 1104 Specifications and Design 1106 Material Procurement 1108 Manufacturing of components and subassemblies 1110 System Integration 1112 Authentication and Transport 1114 Currently in service 1116 Maintenance and inspection 1118 aircraft 1120 High-Level Systems 1122 Internal 1124 Propulsion System 1126 Electrical Systems 1128 Hydraulic System 1130 Environmental Systems

Claims

1. A method (700) for manufacturing an article (119), the method comprising: depositing (704) a wear-resistant material (410, 506, 610) on a surface (404, 504, 604) of the preform (400, 500, 600) by layer-by-layer friction stir deposition to provide an intermediate article (420, 520, 620); machining (706) the intermediate article (420, 520, 620) to remove at least a portion (438, 538, 638) of the wear-resistant material (410, 506, 610) from the intermediate article (420, 520, 620); A method (700).

2. 10. The method of claim 1, wherein the preform comprises a first composition and the wear-resistant material comprises a second composition, the second composition being substantially different from the first composition.

3. 3. The method (700) of claim 1 or 2, wherein the first composition comprises at least one of an aluminum alloy, a titanium alloy, and a steel.

4. 4. The method of claim 1, wherein the wear-resistant material comprises a metal matrix composite, the metal matrix composite comprising a selected one of an aluminum alloy with alumina particles, an aluminum alloy with titanium diboride particles, and an aluminum matrix with a ceramic reinforcement.

5. The step (704) of depositing the wear-resistant material (410, 506, 610) by layer-by-layer friction stir deposition comprises: depositing a first wear-resistant material on the surface (404, 504, 604) of the preform (400, 500, 600); depositing a second wear-resistant material over the first wear-resistant material; 5. The method (700) of any one of claims 1 to 4, comprising:

6. 6. The method (700) of any one of claims 1 to 5, wherein the preform (400, 500, 600) includes partially formed gear teeth (603), and the wear-resistant material (410, 506, 610) is deposited on the partially formed gear teeth (603).

7. 7. The method (700) of any one of claims 1 to 6, wherein the preform (400, 500, 600) is in the form of a gear having gear teeth (432, 532, 632), and the wear-resistant material (410, 506, 610) forms a protective coating layer on the gear teeth (432, 532, 632).

8. 8. The method (700) of any one of claims 1 to 7, further comprising, prior to the step (704) of depositing the wear-resistant material (410, 506, 610) by additive friction stir deposition, a step (802) of depositing a metallic material (564) onto a metallic substrate (563) by additive friction stir deposition to produce the preform (400, 500, 600).

9. 9. The method (700) of any one of claims 1 to 8, wherein the step (704) of depositing the wear-resistant material (410, 506, 610) by additive friction stir deposition comprises plasticizing portions of the preform (400, 500, 600) and the wear-resistant material (410, 506, 610) to produce a mixed interface layer (450, 550, 650) between the preform (400, 500, 600) and the wear-resistant material (410, 506, 610).

10. a gear core (431, 531, 631) having a plurality of gear teeth (432, 532, 632) protruding from the gear core (431, 531, 631); a wear-resistant layer (410, 506, 610) disposed on at least a portion of each gear tooth of the plurality of gear teeth (432, 532, 632); a mixed interface layer (450, 550, 650) defined between the gear core (431, 531, 631) and the wear-resistant layer (410, 506, 610) disposed on the gear core (431, 531, 631); Including gears (430, 530, 630).

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