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<p>Additive manufacturing (AM) has enabled rapid production of complex and high-performance metal components. In this study, the solid-state Additive Friction Stir Deposition (AFSD) process was demonstrated to deposit low-carbon steel CS1018. Process parameters were optimized to improve deposit quality and layer bonding. The AFSD process produced dense, metallurgically bonded CS1018 deposits with a refined ferrite–pearlite microstructure. Compared to the original CS1018 feedstock, the as-deposited material exhibited an ~ 18% lower hardness and ~ 11% lower tensile strength than the feedstock, accompanied by a ~ 78% increase in ductility. These changes are attributed to the AFSD-induced microstructural modifications: specifically, grain refinement and homogeneous dispersion of fine pearlite (Fe₃C) in a ferrite matrix. Post-deposition tempering at 210&#xa0;°C and 518&#xa0;°C produced only modest changes in hardness and tensile behavior relative to the as-deposited state. Changes in XRD peak breadth are consistent with reduced microstrain after tempering. Fractographic analysis revealed that the AFSD deposit’s fracture surface contained finer and more numerous dimples than the feedstock, consistent with its improved toughness. Overall, this work demonstrates that AFSD can successfully deposit low-carbon steel with good mechanical integrity. In addition, this work demonstrates that a moderate heat treatment can primarily serve to stabilize the microstructure and relief stresses without significantly altering the strength or hardness.</p>

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Microstructural evolution and mechanical performance of CS1018 steel processed by additive friction stir deposition and subsequent heat treatment

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年6月20日

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  • Selami Emanet,
  • Saeid Zavari,
  • Huan Ding,
  • Mahnaz Ensafi,
  • Carl Schmidt,
  • Jeff Dulik,
  • Shengmin Guo

摘要

Additive manufacturing (AM) has enabled rapid production of complex and high-performance metal components. In this study, the solid-state Additive Friction Stir Deposition (AFSD) process was demonstrated to deposit low-carbon steel CS1018. Process parameters were optimized to improve deposit quality and layer bonding. The AFSD process produced dense, metallurgically bonded CS1018 deposits with a refined ferrite–pearlite microstructure. Compared to the original CS1018 feedstock, the as-deposited material exhibited an ~ 18% lower hardness and ~ 11% lower tensile strength than the feedstock, accompanied by a ~ 78% increase in ductility. These changes are attributed to the AFSD-induced microstructural modifications: specifically, grain refinement and homogeneous dispersion of fine pearlite (Fe₃C) in a ferrite matrix. Post-deposition tempering at 210 °C and 518 °C produced only modest changes in hardness and tensile behavior relative to the as-deposited state. Changes in XRD peak breadth are consistent with reduced microstrain after tempering. Fractographic analysis revealed that the AFSD deposit’s fracture surface contained finer and more numerous dimples than the feedstock, consistent with its improved toughness. Overall, this work demonstrates that AFSD can successfully deposit low-carbon steel with good mechanical integrity. In addition, this work demonstrates that a moderate heat treatment can primarily serve to stabilize the microstructure and relief stresses without significantly altering the strength or hardness.