Electrically Assisted Friction Stir Deposition for Harder Feedstock
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Solution Overview
Problem
Friction stir additive manufacturing (FSAM) faces challenges in depositing stronger feedstock materials with hardness above a defined grade, as high shear stress and frictional heat lead to tool wear and contamination.
Innovation Solution
The method involves applying an electrical current directly through the feedstock material during the FSAM process, reducing the vertical axial force needed for plasticization and generating heat, which minimizes tool wear and contamination while producing fine microstructures that enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction stir additive manufacturing is used to deposit stronger feedstock materials with higher hardness, then the mechanical properties of the component are improved, but tool wear and contamination increase due to high shear stress and frictional heat
Solution Approach 1:
The feedstock material is preheated to a first temperature before being subjected to friction stir additive manufacturing. This preliminary heating action reduces the material's hardness and makes it more ductile, allowing it to be deposited without causing excessive tool wear or contamination, while still achieving the desired final mechanical properties through controlled cooling and microstructure formation
Solution Approach 2:
The process changes the temperature parameter of the feedstock material from ambient to a first elevated temperature before deposition. This parameter change temporarily reduces the material's hardness and increases its formability, enabling the deposition of stronger materials without the harmful side effects of high shear stress and frictional heat during the forming process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the effective deposition of harder materials with reduced tool wear and contamination, improving the mechanical properties of the deposited components.
Implementation Method 1
applying an electrical current to a feedstock material
Implementation Method 2
applying a vertical axis force to the feedstock material; applying a rotational force to the feedstock material; an application of the vertical axis force and the rotational force causes the feedstock material to heat to a second temperature
Data Source
Figure 1
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AI summary
A method of forming a metal workpiece (113) is disclosed herein. The method includes applying an electrical current (118) through a feedstock material (102), applying a vertical axis force (115) to the feedstock material (102); applying a rotational force (105) to the feedstock material (102), and producing a metallic component (113) from the feedstock material (102) based on the electric current (118), the vertical axis force (115), and the rotational force (105).