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Resource typeJournal Article
Title(s)Fundamental study of multi-track friction surfacing deposits for dissimilar aluminum alloys with application to additive manufacturing
CreatorSoujon, Malte (Institut für Produktionstechnik und -systeme (IPTS), Leuphana Universität Lüneburg  02w2y2t16)
Kallien, Zina  0009-0003-5133-0624 (Helmholtz-Zentrum Hereon  03qjp1d79)
Roos, Arne (Helmholtz-Zentrum Hereon  03qjp1d79)
Zeller-Plumhoff, Berit  0000-0002-7562-9423 (Helmholtz-Zentrum Hereon  03qjp1d79)
Klusemann, Benjamin  0000-0002-8516-5087  142865192 (Institut für Produktionstechnik und -systeme (IPTS), Leuphana Universität Lüneburg  02w2y2t16)
AbstractFriction surfacing is an emerging solid-state coating technology based on frictional heat induced plastic deformation at the tip of a consumable metallic stud that allows to deposit layers with a fine-grained recrystallized microstructure at temperatures below the melting point. The generation of sound, defect-free metallurgical joints between multiple adjacent overlapping friction surfacing deposits, also referred to as multi-track friction surfacing, from dissimilar aluminum alloys is the focus of this experimental work. An extensive volumetric defect analysis is carried out for various overlap configurations, including post-processing strategies in order to assess the inter-track bonding integrity using microscopic characterization techniques and micro-computed tomography. The effect of layer arrangement and overlap distance on the volumetric defect formation in both inter-track and layer-to-substrate interface is quantified and discussed. Post-processing via hybrid friction diffusion bonding process demonstrates a significant reduction in defect volume ratio, proving higher material efficiency. The gained knowledge was used to successfully build a multi-track multi-layer friction surfacing stack, demonstrating the suitability of this process for large-scale additive manufacturing components. The subsequent mechanical analysis reveals excellent homogeneous isotropic tensile properties of the additive structure in the range of the base material tensile strength.
KeywordsMulti-Track Friction Surfacing; Hybrid Friction Diffusion Bonding; MicroCT; Defect Analysis; Tensile Properties; Additive Manufacturing
Year of publication in PubData2024
Publishing typeParallel publication
Publication versionPublished version
Date issued2022-06-07
Creation contextResearch
Published byMedien- und Informationszentrum, Leuphana Universität Lüneburg
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Resource typeJournal
Title of the resource typeMaterials and Design
IdentifierDOI: 10.1016/j.matdes.2022.110786
Publication year2022
Number typeArticle
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