Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts
In the aircraft industry, the high-strength aluminum alloys AA7075 and AA2024 are extensively used for the manufacture of structural parts like stringers and skins, respectively. Additive manufacturing (AM) of the AA7075-T6 aluminum alloy via friction stir deposition to build continuously multilayer...
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MDPI AG
2023-09-01
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| author | Yousef G. Y. Elshaghoul Mohamed M. El-Sayed Seleman Ashraf Bakkar Sarah A. Elnekhaily Ibrahim Albaijan Mohamed M. Z. Ahmed Abdou Abdel-Samad Reham Reda |
| author_facet | Yousef G. Y. Elshaghoul Mohamed M. El-Sayed Seleman Ashraf Bakkar Sarah A. Elnekhaily Ibrahim Albaijan Mohamed M. Z. Ahmed Abdou Abdel-Samad Reham Reda |
| author_sort | Yousef G. Y. Elshaghoul |
| collection | DOAJ |
| description | In the aircraft industry, the high-strength aluminum alloys AA7075 and AA2024 are extensively used for the manufacture of structural parts like stringers and skins, respectively. Additive manufacturing (AM) of the AA7075-T6 aluminum alloy via friction stir deposition to build continuously multilayered parts on a substrate of AA2024-T4 aluminum has not been attempted so far. Accordingly, the present work aimed to explore the applicability of building multilayers of AA7075-T6 alloy on a substrate sheet of AA2024-T4 alloy via the additive friction stir deposition (AFSD) technique and to optimize the deposition process parameters. The experiments were conducted over a wide range of feed rates (1–5 mm/min) and rotation speeds (200–1000 rpm). The axial deposition force and the thermal cycle were recorded. The heat input to achieve the AFSD was calculated. The AA7075 AFSD products were evaluated visually on the macroscale. The microstructures were also investigated utilizing an optical microscope and scanning electron microscope (SEM) equipped with an advanced EDS technique. As well as the presence phases, the mechanical performance of the deposited materials in terms of hardness and compressive strength was also examined. The results showed that the efficiency of the deposition process was closely related to the amount of heat generated, which was governed by the feeding rate, the rotational speed, and the downward force. AA7075 defect-free continuously multilayered parts were produced without any discontinuity defects at the interface with the substrate at deposition conditions of 1, 2, 3, and 4 mm/min and a constant 400 rpm consumable rod rotation speed (CRRS). The additively deposited AA7075-T6 layers exhibited a refined grain structure and uniformly distributed fragment precipitates compared to the base material (BM). The gain size decreased from 25 µm ± 4 for the AA7075-T6 BM to 1.75 µm ± 0.41 and 3.75 µm ± 0.78 for the AFSD materials fabricated at 1 and 4 mm/min deposition feeding rates, respectively, at 400 rpm/min. Among the feeding rates used, the 3 mm/min and 400 rpm rod rotation speed produced an AA7075 deposited part possessing the highest average hardness of 165 HV ± 5 and a compressive strength of 1320 MPa. |
| first_indexed | 2024-03-10T23:04:29Z |
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| institution | Directory Open Access Journal |
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| last_indexed | 2024-03-10T23:04:29Z |
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| spelling | doaj.art-9345346081d5413a99587cb3f6477bac2023-11-19T09:25:10ZengMDPI AGApplied Sciences2076-34172023-09-0113181025510.3390/app131810255Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered PartsYousef G. Y. Elshaghoul0Mohamed M. El-Sayed Seleman1Ashraf Bakkar2Sarah A. Elnekhaily3Ibrahim Albaijan4Mohamed M. Z. Ahmed5Abdou Abdel-Samad6Reham Reda7Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, EgyptDepartment of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, EgyptDepartment of Environmental Engineering, College of Engineering at Al-Leith, Um Al-Qura University, Al-Lith 28434, Saudi ArabiaDepartment of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, EgyptMechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaMechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaDepartment of Production Engineering and Mechanical Design, Faculty of Engineering, Mansoura University, Mansoura 35516, EgyptMechanical Engineering Department, Faculty of Engineering, Suez University, Suez 43518, EgyptIn the aircraft industry, the high-strength aluminum alloys AA7075 and AA2024 are extensively used for the manufacture of structural parts like stringers and skins, respectively. Additive manufacturing (AM) of the AA7075-T6 aluminum alloy via friction stir deposition to build continuously multilayered parts on a substrate of AA2024-T4 aluminum has not been attempted so far. Accordingly, the present work aimed to explore the applicability of building multilayers of AA7075-T6 alloy on a substrate sheet of AA2024-T4 alloy via the additive friction stir deposition (AFSD) technique and to optimize the deposition process parameters. The experiments were conducted over a wide range of feed rates (1–5 mm/min) and rotation speeds (200–1000 rpm). The axial deposition force and the thermal cycle were recorded. The heat input to achieve the AFSD was calculated. The AA7075 AFSD products were evaluated visually on the macroscale. The microstructures were also investigated utilizing an optical microscope and scanning electron microscope (SEM) equipped with an advanced EDS technique. As well as the presence phases, the mechanical performance of the deposited materials in terms of hardness and compressive strength was also examined. The results showed that the efficiency of the deposition process was closely related to the amount of heat generated, which was governed by the feeding rate, the rotational speed, and the downward force. AA7075 defect-free continuously multilayered parts were produced without any discontinuity defects at the interface with the substrate at deposition conditions of 1, 2, 3, and 4 mm/min and a constant 400 rpm consumable rod rotation speed (CRRS). The additively deposited AA7075-T6 layers exhibited a refined grain structure and uniformly distributed fragment precipitates compared to the base material (BM). The gain size decreased from 25 µm ± 4 for the AA7075-T6 BM to 1.75 µm ± 0.41 and 3.75 µm ± 0.78 for the AFSD materials fabricated at 1 and 4 mm/min deposition feeding rates, respectively, at 400 rpm/min. Among the feeding rates used, the 3 mm/min and 400 rpm rod rotation speed produced an AA7075 deposited part possessing the highest average hardness of 165 HV ± 5 and a compressive strength of 1320 MPa.https://www.mdpi.com/2076-3417/13/18/10255additive friction stir depositionAA7075-T6AA2024-T4thermal cyclemacrostructuremicrostructure |
| spellingShingle | Yousef G. Y. Elshaghoul Mohamed M. El-Sayed Seleman Ashraf Bakkar Sarah A. Elnekhaily Ibrahim Albaijan Mohamed M. Z. Ahmed Abdou Abdel-Samad Reham Reda Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts Applied Sciences additive friction stir deposition AA7075-T6 AA2024-T4 thermal cycle macrostructure microstructure |
| title | Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts |
| title_full | Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts |
| title_fullStr | Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts |
| title_full_unstemmed | Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts |
| title_short | Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts |
| title_sort | additive friction stir deposition of aa7075 t6 alloy impact of process parameters on the microstructures and properties of the continuously deposited multilayered parts |
| topic | additive friction stir deposition AA7075-T6 AA2024-T4 thermal cycle macrostructure microstructure |
| url | https://www.mdpi.com/2076-3417/13/18/10255 |
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