Additive friction stir deposition of SS316: Effect of process parameters on microstructure evolution

Abstract

Solid state nature of additive friction stir deposition (AFSD) additive manufacturing process is very advantageous in terms of defect formation and microstructural refinement in the material. Current study presents the process optimization, microstructural evolution and kinetics of recrystallization for AFSD deposited low stacking fault energy material - SS316. As deposited microstructure shows equiaxed ultra fine grains with an average grain size of ~5.0 ± 0.5 μm. Shear deformation at high temperature during processing leads to the operation of restoration mechanisms. Observation of necklace type microstructure in the as deposited SS316 is attributed to discontinuous dynamic recrystallization during processing. Recrystallization kinetics of the AFSD SS316 is characterized using Johnson-Mehl-Avarami-Kolmogorov (JMAK) model. Deformation – thermal cycling during AFSD process resulted in inconsistent recrystallization kinetics. Variation in strain, strain rate and temperature during processing with processing parameters result in varying microstructure and tool wear. High strength-ductility combination and sustained work hardening in as deposited SS316 appear to arise from transformation and twinning during deformation, leading to the formation of hierarchical twins and martensitic phase after deformation. • A high strength and work hardening alloy – SS316 is additively manufactured using a novel additive friction stir deposition. • Porosity free builds with fine equiaxed grain structure is formed in as deposited material as a result of discontinues dynamic recrystallization during processing. • Microstructure of the deposited material and the tool wear during processing varied with variation in the process parameters. • Activation of twining and transformation during deformation resulted in excellent tensile properties with yield strength of 415 ± 10 MPa and ductility 75 ± 5% in as deposited material.