Multimodal defect analysis and application of virtual machining for solid-state manufactured aluminium structure.

ABSTRACT: Additive friction stir deposition (AFSD) is an emerging solid-state non-fusion additive manufacturing (AM) technology, which produces parts with wrought-like material properties, high deposition rates, and low residual stresses. However, impact of process interruption on defect formation and mechanical properties has not yet been well addressed in the literature. In this study, Al6061 aluminium structure with two final heights and deposition interruption is successfully manufactured via AFSD and characterised. Defect analysis conducted via optical microscopy, electron microscopy, and X-ray computed tomography reveals > 99% relative density with minimal defects in centre of the parts. However, tunnel defects at interface between substrate and deposit as well as kissing bonds are present. Ed

SUBMITTER: Yakubov V 

PROVIDER: S-EPMC12267324 | biostudies-literature | 2025

REPOSITORIES: biostudies-literature