Efficient Build-Up of High-Strength Aluminum Structures Using Friction Stir Additive Manufacturing

Friction Stir Additive Manufacturing (FSAM) is a novel process with which large-scale aluminum structures can be produced from high-strength alloys such as the 7xxx series. Due to prevalence of these in airplanes and rockets, offers high application potential, for example fabricating stringers stiffeners. The building FSAM characterized by sequentially stacking friction stir lap welding (FSLW) metal sheets. Before adding next layer, surface machined (i.e., milling). So far, this necessary step enable gap-free layers, results increased costs reduced layer heights. investigations described paper were aimed at improving weld quality defect-free without additional machining step. For this, FSLW was conducted using different tools. resulting welds evaluated based on superficial internal characteristics well mechanical properties (shear strength). With tool both rotating stationary shoulder combined, seams mean underfill flash height 0.07 mm produced. In subsequent study, it proven that possible up fifth combined tool.