Abstract

In this work, the effect of processing parameters on the resulting microstructure and mechanical properties of magnesium alloy WE43 processed via Additive Friction Stir Deposition (AFSD), a nascent solid-state additive manufacturing (AM) process, is investigated. In particular, a parameterization study was carried out, using multiple four-layer deposits, to identify a suitable process window for a structural 68-layers bulk WE43 deposition. The parametric study identified an acceptable set of parameters with minimal surface defects and excellent consolidation for the fabrication of a bulk WE43 deposition. Microstructural, tensile, and fatigue life characterization was conducted on the bulk WE43 deposition and compared to commercially available wrought material to elucidate the process-structure-property-performance (PSPP) relationship of the AFSD process. This study shows that the bulk WE43 deposit exhibited a refined homogenous microstructure and a texture shift relative to the wrought material. However, a reduction in hardness and tensile behavior was observed in the as-deposited WE43 compared to the wrought control. Additionally, fatigue specimens extracted from the bulk deposition exhibited a decrease in life in the low-cycle regime but performed comparably to the wrought plate in the high-cycle regime. The outcomes of this study illustrate the potential of the AFSD process in additively manufactured structural load-bearing components made with magnesium alloy WE43 in the as-built condition.

Highlights

  • IntroductionMicrostructural, tensile, and fatigue life characterization was conducted on the bulk WE43 deposition and compared to commercially available wrought material to elucidate the process-structure-property-performance (PSPP) relationship of the Additive Friction Stir Deposition (AFSD) process

  • Academic Editors: Evgeny and Department of Mechanical Engineering, The University of Alabama, Tuscaloosa, AL 35478, USA; Manufacturing at the Point-of-Need Center (MPNC), The University of Alabama, Tuscaloosa, AL 35487, USA

  • Similar Additive Friction Stir Deposition (AFSD) parameters for Mg Alloy AZ31 reported by Robinson et al were used as an initial baseline for the parametric study [22]

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Summary

Introduction

Microstructural, tensile, and fatigue life characterization was conducted on the bulk WE43 deposition and compared to commercially available wrought material to elucidate the process-structure-property-performance (PSPP) relationship of the AFSD process. In traditional manufacturing methods of magnesium alloys, several issues arise, including hot cracking, porosity, and limited cold working ability, in addition to high costs, which has limited the development and usability of these alloys [4,5,6,7]. To combat these issues, there has recently been a push for the rapid manufacturing of magnesium alloys using various additive techniques

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