| Abstract Scope |
Additive friction stir deposition is an emerging solid-state process for the creation of geometric features utilized in additive manufacturing and advanced structural repair. This work pioneers the technical development of small-scale additive friction stir deposition including machine design and tooling to process miniaturized feedstock. The successful deposition of high strength martensite steel, high strength aluminum, and other high performance alloys are demonstrated in this work to highlight the process capabilities and to present how design challenges in downscaling, e.g., feed-rod buckling, substrate preheating, heat generation, miniaturized feeding mechanics, and process stability, are addressed. Further, in-situ monitoring of temperature, force evolution and torque generation is utilized to enable the study of thermal and mechanical process physics. The advanced machine design results in an innovative feeding mechanism without cantilevered sections of the feed-rod. |