Hybrid Metal Extrusion & Bonding (HYB) - a new technology for solid-state additive manufacturing of aluminium components

Abstract

This paper demonstrates a concept for a new additive manufacturing process for aluminium alloys, based on the Hybrid Metal Extrusion & Bonding (HYB) technology, along with the potential for further development of the process. The process is capable of producing near net shape structures at high deposition rates, utilizing metallic bonding to consolidate the feedstock to the substrate in the solid-state. The aluminium feedstock wire is processed through a specially designed extruder, which serves the purpose of dispersing inherent oxides of both the feedstock and the substrate. At the same time it provides sufficient pressure for metallic bonding to occur. The process has been tested on a concept level by successfully depositing a two-layered structure of commercial purity aluminium.