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<p>This study investigates the potential of multi-track Friction Stir Additive Manufacturing (FSAM) for the fabrication of high-performance aluminum alloy structures tailored different industrial applications. Thick-walled monomaterial aluminum components, vital for airframe and fuselage subassemblies, were fabricated using AA6061-T6 via FSAM under varied processing conditions-rotational speeds of 875 and 1230&#xa0;rpm, and traverse speeds of 41 and 82&#xa0;mm/min. The research focuses on optimizing toolpath overlap strategies to ensure superior material consolidation and enhanced through-thickness properties critical for aerospace loading scenarios. The additive process yielded fine-grained equiaxed microstructures (~ 5&#xa0;μm), with further refinement (~ 2&#xa0;μm) localized at interlayer regions due to intensified stirring. Microstructural evolution was dominated by continuous and geometric dynamic recrystallization mechanisms, followed by dynamic recovery, enabling a stable and homogeneous grain structure. A high proportion of high-angle grain boundaries (~ 75%) confirmed effective recrystallization, while a strong {111} texture at interlayer boundaries improved crystallographic alignment, particularly under optimized parameter. The mechanical properties demonstrated a balanced enhancement compared to BM, across the process window. The highest improvements observed across all parameter sets were ~ 24% in hardness, ~ 32% in tensile strength, and ~ 88% in impact toughness increased representing the upper bounds of the processed conditions. Fractography relealed the ductile failure mechanism, which is indicative of enhanced energy absorption and damage tolerance. The grain evolution model has been identified for this process to understand the microstructural changes occur during the repititaive thermo-mechanical conditioning along the build height.</p> Graphical abstract <p></p>

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Enhanced mechanical properties of the friction stir additively manufactured aluminium thick walls through severe plastic deformation

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Ankan Das,
  • Himangshu Kalita,
  • Sanjay Raj,
  • Sajan Kapil,
  • Pankaj Biswas

摘要

This study investigates the potential of multi-track Friction Stir Additive Manufacturing (FSAM) for the fabrication of high-performance aluminum alloy structures tailored different industrial applications. Thick-walled monomaterial aluminum components, vital for airframe and fuselage subassemblies, were fabricated using AA6061-T6 via FSAM under varied processing conditions-rotational speeds of 875 and 1230 rpm, and traverse speeds of 41 and 82 mm/min. The research focuses on optimizing toolpath overlap strategies to ensure superior material consolidation and enhanced through-thickness properties critical for aerospace loading scenarios. The additive process yielded fine-grained equiaxed microstructures (~ 5 μm), with further refinement (~ 2 μm) localized at interlayer regions due to intensified stirring. Microstructural evolution was dominated by continuous and geometric dynamic recrystallization mechanisms, followed by dynamic recovery, enabling a stable and homogeneous grain structure. A high proportion of high-angle grain boundaries (~ 75%) confirmed effective recrystallization, while a strong {111} texture at interlayer boundaries improved crystallographic alignment, particularly under optimized parameter. The mechanical properties demonstrated a balanced enhancement compared to BM, across the process window. The highest improvements observed across all parameter sets were ~ 24% in hardness, ~ 32% in tensile strength, and ~ 88% in impact toughness increased representing the upper bounds of the processed conditions. Fractography relealed the ductile failure mechanism, which is indicative of enhanced energy absorption and damage tolerance. The grain evolution model has been identified for this process to understand the microstructural changes occur during the repititaive thermo-mechanical conditioning along the build height.

Graphical abstract