Monday  |  Executive AB  |  05:40 PM–06:00 PM

#19285, A Novel Extrusion-based Solid-state Additive Manufacturing with High Build Rates: Processing, Mechanical Properties and Microstructure

Solid-state additive manufacturing (AM) enables a defect-free solid build with a refined, equiaxed, and wrought microstructure at higher build rates compared to fusion based AM. A novel extrusion-based SolidStir® AM technique is introduced in the current work and applied to Al alloys in general, and Al-Ce alloys in particular. SolidStir® AM is based on friction-stir heating where a specially designed non-consumable rotating tool introduced inside the die-chamber generates heat due to contact friction with the feedstock material. The heated material undergoes severe plastic deformation due to synergistic activities of strain, strain rate, and temperature. The softened material is pushed down the die-throat by virtue of spiral features on the tool which is further shear deposited on the substrate. The work is supplemented by detailed mechanical performance evaluation along all three directions of the build and the properties are compared with the starting feedstock material. The AM process resulted in a refined equi-axed microstructure and completely broke down the eutectic network that was present in the as-cast microstructure in Al-Ce alloys. The effect of post-process heat treatment on the precipitation kinetics and the influence on mechanical properties will be addressed. Advantages of SolidStir® AM against the existing state of the art solid-state AM techniques will be discussed based on the microstructure and mechanical properties.

Ravi Sankar Haridas   University of North Texas
Anurag Gumaste   University of North Texas
Pankaj Kulkarni   Enabled Engineering
Devin Davis   Enabled Engineering
Kumar Kandasamy   Enabled Engineering
Vijay Vasudevan   University of North Texas
Rajiv Mishra   University of North Texas