Hybrid heat-source solid-state additive manufacturing: A method to fabricate high performance AA6061 deposition

doi:10.1016/j.jmst.2024.11.079

Abstract

Abstract: An approach called hybrid heat-source solid-state additive manufacturing (HHSAM) for fabricating multilayer AA6061 deposition with superior properties is proposed in this paper. As compared with the traditional additive friction stir deposition (AFSD), the auxiliary induction heat-source in HHSAM effectively improves the temperature and fluidity of plastic flow, which facilitates the formation and enrichment of residual Mg₂Si phases besides Al(Fe,Mn)Si, promotes the dynamic recrystallization and increases the bonding strength between layers during the deposition process. Therefore, the HHSAM depositions possess a more uniform structure, superior integral mechanical properties and corrosion resistance after heat treatment process. Moreover, HHSAMed specimens avoid abnormal grain growth (AGG) in heat treatment process, which is regularly encountered in the traditional AFSD. HHSAM method is proved to be a new solid-state additive manufacturing method with good developing prospects for fabricating alloy production with excellent properties in a high-efficiency manner.

Key words: Hybrid heat-source solid-state additive manufacturing, Additive friction stir deposition, Mechanical properties, Corrosion resistance

Qian Qiao, Chan Wa Tam, Wai I Lam, Kaiyuan Wang, Dawei Guo, Chi Tat Kwok, Yongyong Lin, Guoshun Yang, Hongchang Qian, Dawei Zhang, Xiaogang Li, Lap Mou Tam. Hybrid heat-source solid-state additive manufacturing: A method to fabricate high performance AA6061 deposition[J]. J. Mater. Sci. Technol., 2025, 228: 107-124.

References

[1] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Templesmith, C.J. Dawes, Patent Application No. 9125978.8, 1991.
[2] M.N. Ilman, M.R. Muslih, Int. J. Lightweight Mater.Manuf. 7(2024) 668.
[3] S.P. Dwivedi, S. Sharma, A. Singh, Mater. Chem. Phys. 315(2024) 129038.
[4] M. Liu, B.B. Wang, X.H. An, P. Xue, F.C. Liu, L.H. Wu, Z.Y. Ma, Mater. Sci. Eng. A 857 (2022) 144088.
[5] Z. Zhang, Z.J. Tan, J.Y. Li, Y.F. Zu, J.J. Sha, Acta Metall. Sin.-Eng. Lett. 33(2022) 75-87.
[6] E. Bishop, Weld. J. 28(1960) 408-410.
[7] P. Pirhayati, H.J. Aval, Mater. Res. Express 6 (2019) 056550.
[8] W. Tang, X. Yang, C. Tian, C. Gu, Mater. Sci. Eng. A 860 (2022) 144237.
[9] R. Xie, T. Liang, S. Chen, H. Liu, Addit. Manuf. 67(2023) 103496.
[10] H. Liu, Y. Liu, T. Liang, R. Xie, B. Liu, Z. Wang, S. Chen, J. Manuf. Process. 119(2024) 305-320.
[11] A. Behvar, S.I. Shakil, H. Pirgazi, M. Norfolk, M. Haghshenas, Int. J. Adv. Manuf. Technol. 132(2024) 2061-2075.
[12] H. Chen, X. Meng, J. Chen, Y. Xie, J. Wang, S. Sun, Y. Huang, Addit. Manuf. 70(2023) 103557.
[13] R.F. Vaz, A. Garﬁas, V. Albaladejo, J. Sanchez, I.G. Cano, Coatings 13 (2023) 267.
[14] B.T. Mengiste, A. Arab, Y. Guo, Y. Lei, X. Li, P. Chen, J. Xie, J. Alloy. Compd. 980(2024) 173627.
[15] N. Tuncer, A. Bose, JOM 72 (2020) 3090-3111.
[16] H. Ghadimi, M. Talachian, H. Ding, S. Emanet, S. Guo, Metals 14 (2024) 101.
[17] J. Adamowski, M. Szkodo, J. Achieve. 20(2007) 403-406.
[18] J. Gandra, H. Krohn, R.M. Miranda, P. Vilaça, L. Quintino, J.F. dos Santos, J.Mater. Process. Technol. 214(2014) 1062-1093.
[19] H.Z. Yu, R.S. Mishra, Mater. Res. Lett. 9(2021) 71-83.
[20] O. Cakmak, S.H. Lee, S.G. Chung, D.R. Eo, H. Yeom, J.W. Cho, Mater. Des. 240(2024) 112862.
[21] T. Zhao, Z. Yan, B. Zhang, P. Zhang, R. Pan, T. Yuan, S. Chen, J. Manuf. Process. 119(2024) 235-254.
[22] V. Rubtsov, A. Chumaevskii, E. Knyazhev, V. Utyaganova, D. Gurianov, A. Amirov, E. Kolubaev, Metals 14 (2024) 105.
[23] P. Agrawal, C.H. Shiau, A. Sharma, Z. Hu, M. Dubey, Y. Lu, R.S. Mishra, Mater. Des. 238(2024) 112730.
[24] N. Gotawala, Z.Y. Hang, J. Manuf. Process. 101(2023) 114-127.
[25] J.K. Yoder, G.D. Hahn, N. Zhao, R.E. Brennan, K. Cho, Z.Y. Hang, Addit. Manuf. Lett. 1(2023) 100108.
[26] P. Agrawal, R.S. Haridas, S. Yadav, S. hapliyal, S.Gaddam, R. Verma, R.S. Mishra, Addit. Manuf. 1(2021) 102259.
[27] P. Agrawal, R.S. Haridas, S. Yadav, S. Thapliyal, S. Gaddam, R. Verma, R.S. Mishra, Addit. Manuf. 47(2021) 102259.
[28] Q. Qiao, M. Zhou, X. Gong, S. Jiang, Y. Lin, H. Wang, W.I. Lam, H. Qian, D. Guo, D. Zhang, C.T. Kwok, L.M. Tam, Addit. Manuf. 84(2024) 104141.
[29] B.J. Phillips, C.J. Williamson, R.P. Kinser, J.B. Jordon, K.J. Doherty, P.G. Allison, Materials 14 (2021) 6732.
[30] M.B. Williams, T.W. Robinson, C.J. Williamson, R.P. Kinser, N.A. Ashmore, P.G. Allison, J.B. Jordon, Metals 11 (2021) 1739.
[31] B. Chaudhary, M. Patel, N.K. Jain, J. Murugesan, V. Patel, in: Solid State Additive Manufacturing, CRC Press, 2023, pp. 127-168.
[32] G. Laplanche, J. Bonneville, C. Varvenne, W.A. Curtin, E.P. George, Acta Mater. 143(2018) 257-264.
[33] G. Çam, Int. Mater. 56(2011) 1-48.
[34] S.Z. Uddin, L.E. Murr, C.A. Terrazas, P. Morton, D.A. Roberson, R.B. Wicker, Ad- dit. Manuf. 22(2018) 405-415.
[35] X. Bai, H. Zhang, G. Wang, Int. J. Adv. Manuf. Technol. 77(2015) 717-727.
[36] Y. Sun, H. Liu, R. Xie, Y. Chen, S. Chen, J. Mater. Sci.Technol. 205(2024) 168-181.
[37] K. Sadeghipour, J.A. Dopkin, K. Li, Comput. Ind. 28(1996) 195-205.
[38] A. Masserey, J. Rappaz, R. Rozsnyo, R. Touzani, IEEE Trans. Magn. 40(2004) 1664-1671.
[39] S.L. Semiatin, Elements of Induction Heating: Design, Control, and Applications, ASMInternational, 1988.
[40] Q. Qiao, Q. Liu, J. Pu, H. Shi, W. Li, Z. Zhu, D. Guo, H. Qian, D. Zhang, X. Li, C. T. Kwok, L.M. Tam, Mater. Genome. Eng. Adv. 2(2024) e31.
[41] J. Codrington, P. Nguyen, S.Y. Ho, A. Kotousov, Appl. Therm. Eng. 29(2009) 2783-2789.
[42] V.G.Vijay Prakaash, A.Vignesh, A.K. Lakshminarayanan, V. Balasubramanian, Appl. Mech. Mater. 787(2015) 0401-0405.
[43] A. Polozine, L. Schaeffer, J. Mater. Process.Technol. 170(2005) 611-615.
[44] C.A. Crane, M.L. Pantoya, J. Dunn, Int. J. Therm. Sci. 49(2010) 1877-1885.
[45] ASTM, in: Annu B ASTM Stand, 2010, pp. 1-27.
[46] American Society for Testing and Materials, ASTM, West Conshohocken, PA, USA, 2014.
[47] Y.F. Sun, J.M. Shen, Y. Morisada, H. Fujii, Mater. Des. 54(2014) 450-457.
[48] D. Guo, W.I. Lam, C.T. Kwok, S.L.I.Chan, W. Li, G.Yang, L.M. Tam, Surf. Coat. Technol. 441(2022) 128511.
[49] G.D. Hahn, K.P. Knight, N. Gotawala, Z.Y. Hang, Mater. Sci. Eng. A 896 (2024) 146268.
[50] G. Han, J.R. Lee, Y. Noh, T.S. Jun, Mater. Sci. Eng. A 840 (2022) 142896.
[51] R.K. Singh, S.S.S. Guraja, O.O. Ajide, G.M. Owolabi, N. Kumar, Mater. Sci. Eng. A 865 (2023) 144636.
[52] W. Tang, X. Yang, C. Tian, Y. Xu, Mater. Charact. 196(2023) 112646.
[53] D.K. Yaduwanshi, S. Bag, S. Pal, J. Mater. Eng.Perform. 23(2014) 3794-3803.
[54] D. Guo, C.T. Kwok, S.L.I.Chan, Mater. Des. 182(2019) 108037.
[55] J. Zhu, W. Jiang, G. Li, F. Guan, Y. Yu, Z. Fan, J. Mater. Process.Technol. 283(2020) 116699.
[56] D. Liu, X. Lai, Z. Huang, L. Yang, K. Zhou, Adv. Eng. Mater. 26(2024) 2301607.
[57] X.M. Chen, Y.C. Lin, M.S. Chen, H.B. Li, D.X. Wen, J.L. Zhang, M. He, Mater. Des. 77(2015) 41-49.
[58] B. Wang, P. Zhu, Y. Cao, L. Zhou, P. Xue, L. Wu, J. Mater. Process.Technol. 26(2023) 6096-6107.
[59] L. Chen, L. Lu, L. Zhu, Z. Yang, W. Zhou, X. Ren, X. Zhang, Metall. Mater. Trans. A 55 (2024) 1049-1064.
[60] A .S. Sundar, A.Kar, K.K. Mugada, A. Kumar, Mater. Charact. 203(2023) 113148.
[61] S. Pogatscher, H. Antrekowitsch, H. Leitner, D. Pöschmann, Z.L. Zhang, P.J.Ug- gowitzer, Acta Mater. 60(2012) 4496-4505.
[62] H.J. Zhang, S.L. Sun, H.J. Liu, Z. Zhu, Y.L. Wang, J. Manuf. Process. 60(2020) 544-552.
[63] Y.S. Park, S.B. Lee, N.J. Kim, Mater. Trans. 44(2003) 2617-2624.
[64] K. Matsuda, T. Kawabata, Y. Uetani, T. Sato, S. Ikeno, J. Mater. 37(2002) 3369-3375.
[65] J. Wang, X. Chen, L. Yang, G. Zhang, Mater. Sci. Eng. A 841 (2022) 143081.
[66] F.J. Liu, Z.Y. Sun, Y.F. Tuo, Y. Ji, Y.X. Bai, Int. J. Adv. Manuf. Technol. 106(2020) 1465-1476.
[67] L. Chen, Y. Li, L. Lu, Z. Yang, X. Ren, X. Zhang, Mater. Today Commun. 38(2024) 108078.
[68] B.E.T.Roper, C.M. Roper, H.M. Rao, L.N. Brewer, V.K. Vasudevan, N. Zhu, P.G. Al- lison, Metallogr. Microstruct. Anal. 13(2024) 174-180.
[69] S. Raj, P. Biswas, J. Manuf. Sci.Eng. 144(2022) 041014.
[70] X. Zhang, H. Wang, B. Yan, C. Zou, Z. Wei, Mater. Sci. Eng. A 822 (2021) 141641.
[71] T. Shiraiwa, S. Kato, F. Briffod, M. Enoki, Sci. Technol. Adv. Mater. 2(2022) 175-197.
[72] A. Reilly, H. Shercliff, Y. Chen, P. Prangnell, J. Mater. Process.Technol. 225(2015) 473-484.
[73] S.C. Beck, B.A. Rutherford, D.Z. Avery, B.J. Phillips, H. Rao, M.Y. Rekha, J.B. Jor- don, Mater. Sci. Eng. A 819 (2021) 141351.
[74] B. Chaudhary, M. Patel, N.K. Jain, J. Murugesan, V. Rana, JOM 75 (2023) 4782-4792.
[75] F. Wang, J. Wei, G. Wu, M. Qie, C. He, Mater. Lett. 342(2023) 134312.
[76] M. Rosito, M. Vanzetti, E. Padovano, F. Gili, R. Sampieri, F. Bondioli, C.F. Badini, Metals 13 (2023) 1128.
[77] U. Patakham, A. Palasay, P. Wila, R.J.M.S. Tongsri, Mater. Sci. Eng. A 821 (2021) 141602.
[78] M. Yu, X. Li, K. Wen, B. Xiong, Z. Li, L. Yan, H. Liu, Mater. Lett. 275(2020) 128074.
[79] B. Wang, F. Pan, X. Chen, W. Guo, J. Mao, Mater. Sci. Eng. A 656 (2016) 165-173.
[80] Z. Nikseresht, F. Karimzadeh, M.A. Golozar, M. Heidarbeigy, Mater. Des. 31(2010) 2643-2648.
[81] A. Hamada, L. Karjalainen, M. Somani, Mater. Sci. Eng. A 431 (2006) 211-217.
[82] M. Atapour, H. Sarlak, M. Esmailzadeh, Int. J. Adv. Manuf. Technol. 83(2016) 721-728.
[83] C. Peng, G. Cao, T. Gu, C. Wang, Z. Wang, C. Sun, J. Mater. Res.Technol. 19(2022) 709-721.
[84] J. Mayén, M. Hernández-Hernández, A. Del Carmen Gallegos-Melgar, I.Pereyra, E. Barredo, A. Abundez-Pliego, J. Porcayo-Calderón, Trans. Indian Inst. Met. 75(2022) 2725-2735.
[85] V. Shrivastava, G.K. Gupta, I.B. Singh, J. Alloy. Compd. 775(2019) 628-638.