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Book Title TMS 2020 149th Annual Meeting & Exhibition Supplemental Proceedings
Series Title
Chapter Title Additive Manufacturing of Aluminum Using Friction Stir Deposition
Copyright Year 2020
Copyright HolderName The Minerals, Metals & Materials Society
Author Family Name Elfishawy
Particle
Given Name Ebtessam
Prefix
Suffix
Role
Division Metallurgical and Materials Engineering Department, Faculty of Petroleum
and Mining Engineering
Organization Suez University
Address 43511, Suez, Egypt
Division Mechanical Engineering Department
Organization The American University in Cairo
Address AUC, Avenue, 11835, New Cairo, Egypt
Email
Corresponding Author Family Name Ahmed
Particle
Given Name M. M. Z.
Prefix
Suffix
Role
Division Metallurgical and Materials Engineering Department, Faculty of Petroleum
and Mining Engineering
Organization Suez University
Address 43511, Suez, Egypt
Division Mechanical Engineering Department
Organization The British University in Egypt
Address al-Shorouk, 11837, Cairo, Egypt
Division SSMMR-CSE
Organization Suez University
Address 43511, Suez, Egypt
Email Mohamed.Zaky@bue.edu.eg
Author Family Name Elsayed Seleman
Particle
Given Name M. M.
Prefix
Suffix
 Role
Division Metallurgical and Materials Engineering Department, Faculty of Petroleum
and Mining Engineering
Organization Suez University
Address 43511, Suez, Egypt
Division SSMMR-CSE
Organization Suez University
Address 43511, Suez, Egypt
Email

Abstract In the current work, additive manufacturing process using friction stir deposition technique from die-cast
Al–Si bar of 20 mm diameter against aluminum substrate was carried out. The effect of the spindle rotation
speed (1200 rpm) and the feeding speed (3–5 mm/min) on the deposition process, the microstructure, and
the hardness of the friction deposited parts were investigated. During the additive manufacturing process,
after fixing the bar on the spindle shank and while rotating, the bar approaches the substrate at a constant
feeding speed, and the bar plastically deformed due to the friction between the rotating bar and the fixed
substrate under the effect of axial loading that causes the material to transfer from the bar to the substrate
under the continuous feeding and the severe plastic deformation. This has resulted in a successful additive
manufacturing of three cylindrical parts of 25 mm diameter of different heights at the different feeding
rates. The additive manufactured parts (AMPs) were found to have a sound structure with ultra-fine grains.
Keywords Additive manufacturing - Friction stir deposition - Friction stir welding - Friction stir processing -
Aluminum alloys - Hardness
 Additive Manufacturing of Aluminum
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Using Friction Stir Deposition

Ebtessam Elfishawy, M. M. Z. Ahmed and M. M. Elsayed Seleman

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1 Abstract In the current work, additive manufacturing process using friction stir
2 deposition technique from die-cast Al–Si bar of 20 mm diameter against aluminum
3 substrate was carried out. The effect of the spindle rotation speed (1200 rpm) and
4 the feeding speed (3–5 mm/min) on the deposition process, the microstructure, and
5

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the hardness of the friction deposited parts were investigated. During the additive
manufacturing process, after fixing the bar on the spindle shank and while rotating,
the bar approaches the substrate at a constant feeding speed, and the bar plastically
8 deformed due to the friction between the rotating bar and the fixed substrate under
9 the effect of axial loading that causes the material to transfer from the bar to the
10 substrate under the continuous feeding and the severe plastic deformation. This has
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11 resulted in a successful additive manufacturing of three cylindrical parts of 25 mm
12 diameter of different heights at the different feeding rates. The additive manufactured
13 parts (AMPs) were found to have a sound structure with ultra-fine grains.

Keywords Additive manufacturing · Friction stir deposition · Friction stir

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15 welding · Friction stir processing · Aluminum alloys · Hardness

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E. Elfishawy · M. M. Z. Ahmed (B) · M. M. Elsayed Seleman

Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining
Engineering, Suez University, 43511 Suez, Egypt
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e-mail: Mohamed.Zaky@bue.edu.eg
E. Elfishawy
Mechanical Engineering Department, The American University in Cairo, AUC, Avenue, 11835
New Cairo, Egypt
M. M. Z. Ahmed
Mechanical Engineering Department, The British University in Egypt, al-Shorouk, 11837 Cairo,
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Egypt
M. M. Z. Ahmed · M. M. Elsayed Seleman
SSMMR-CSE, Suez University, 43511 Suez, Egypt

© The Minerals, Metals & Materials Society 2020 1

The Minerals, Metals & Materials Society (ed.), TMS 2020 149th
Annual Meeting & Exhibition Supplemental Proceedings, The Minerals,
Metals & Materials Series, https://doi.org/10.1007/978-3-030-36296-6_21

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 2 E. Elfishawy et al.

Introduction
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17 The industrial history can be classified into periods separated by four industrial
18 revolutions; the first revolution starts with the transition from manual production to
19 steam-driven manufacturing between 1760 and 1830, the second technical revolution

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20 was ignited by the development of large scale material and energy production between
21 1840 and 1940, the third digital-driven revolution was initiated by transferring from
22 analog, mechanical, and electronic systems to highly connected digital technology
23 which starts from 1945 up to now, and the fourth industrial revolution which is known
24 as direct digital manufacturing starts since 2010 which was driven by embracing

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25 much contemporary automation, data interconnectivity, and advanced manufacturing
26 technologies [1]. In the fourth industrial revolution, additive manufacturing (AM)
27 is considered as the key component for technological applications [2, 3]. Fusion
28 beam-based AM methods are the most techniques used for metal-based AM [4].
29 However, achieving high structural performance is a main challenge because the
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liquid–solid phase transformation that makes their structural properties is limited
by solidification microstructures[5]. Moreover, Anisotropic mechanical properties
and high cost of powder manufacturing and preparation are another challenges that
33 increase the gap between the beam-based AM capabilities and the industrial demand.
34 That’s why, solid-state AM technique has been introduced as a promising application
of non-beam-based AM to bridge these gaps [2, 6]. As per the American Society for
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36 Testing and Materials (ASTM) classification, there are seven techniques of additive
37 manufacturing. But the main approaches for metals and alloys manufacturing are the
38 beam-based technologies such as powder bed fusion and directed energy deposition
39 [1]. Those techniques are considered as high-energy and high-temperature processes
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40 which depend on melting the metal powder by laser or electron beam [7, 8]. As
41 result of the rapid epitaxial solidification of the metal, the microstructure of the
42 final product is highly orientated with columnar grains and anisotropic mechanical
43 properties [1, 2, 7].
44 As most applications require isotropic mechanical properties, the non-beam-based
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45 solid-state additive processes have been developed to provide the isotropic structure
46 required and to avoid the other limitations of beam-based additive manufacturing like
47 the high-cost and time-consuming process of preparing suitable powders, in addition
48 to the difficulty of fabricating non-weldable alloys, such as 2xxx or 7xxx Al alloys
49 [2]. Afterwards, solid-state additive manufacturing has lagged behind in the form of
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50 friction stir additive manufacturing depending on the main concept of friction stir
51 welding and friction stir processing [9, 10].
52 In 2011, Dilip et al. [11] succeeded to build a solid cylinder of 20 mm dia and
53 50 mm height with more than 30 layers by friction deposition using a 19-mm-diameter
54 consumable rod of austenitic stainless steel AISI 304 against a mild steel substrate of
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55 dia (25 mm) and the following parameters: 800 rpm spindle rotation speed, 9.8 kN
56 ton friction force, and 3 mm burn-off were used [12]. Non-beam-based additive
57 manufacturing has many techniques; one of them is the seam welding of multi-layered
58 similar and dissimilar metallic sheets which has been introduced by Prasad et al. in

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 Additive Manufacturing of Aluminum Using Friction Stir Deposition 3

2015. In their study, a defect-free, metallurgically bonded, multi-track, and multi-

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60 metal seam welds were obtained of relatively high-temperature melting materials,

61 AISI 304, C-Mn steels, Ni-based alloys, CP Cu, CPNi, Ti6Al4V, and relatively low-
62 temperature melting material, AA6061. This process depends on the rotation of non-
63 consumable rod (CP Mo or AISI 304) against the upper sheet of a clamped metallic

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64 stack [13]. Then, an axial force was applied once the distal end of the rod touched
65 the top portion of the upper metallic sheet. And to get the desired welding length,
66 the metallic stack moved horizontally relative to the stationery non-consumable rod
67 after an initial dwell time causing the metallurgical bonding between the metallic
68 sheets which was attributed to localized stick and slip at the interface, dynamic

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69 recrystallization, and diffusion. The mechanical tensile shear testing showed that
70 the seam welds were generally stronger than the base metal counterparts [13]. In
71 2015, using friction deposition, Karthik et al. [14] succeeded to make a metal–
72 metal composite of aluminum matrix with titanium particle reinforcement (6 vol.%
73 Tip/AA5083). The friction deposited multi-layer composite microstructure was very
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fine grain size including uniformly distributed titanium particles without any harmful
intermetallic formation at the reinforcement/matrix interfaces. The produced layers
were well-bonded. [14].
77 Another technique of additive manufacturing was developed in 2017 by Bandari
78 et al. [15], who have worked on commercial pure aluminum with a thickness of 6 mm
79 as the base plate and TiC particles of average size 44 m which were used as rein-
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80 forcement to form tailor-made functionally graded composites by friction stirring.
81 In addition to control reinforcement particle volume fraction using a mathemati-
82 cal model by managing their distribution in a matrix and counting on the ability of
83 friction stirring for local homogenization that leads to property gradients, Sharma
et al. [15] also concluded that the parameters which affect mixing of particles and
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85 grain size of matrix are the particle size [16, 17], volume fraction, number of stirring
86 passes, and change or continuation of tool traverse direction in successive passes.
87 While those that affect the mechanical properties are continuous dynamic recrys-
88 tallization by helping grains to grow, crushing of reinforcement particles restricts
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89 grain boundary migration and crushing of the initial matrix grain. Hence, changes
90 in local properties can be controlled by achieving control over the volume fraction.
91 Therefore, the observed defects after initial pass of stirring like cracks and voids can
92 be eliminated after multiple passes. This developed approach results in gradients in
93 mechanical properties such as yield stress, Young’s modulus, and the strain harden-
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94 ing coefficient which can be evaluated with the digital image correlation technique
95 [15].
96 Recently, Rivera et al. [18] have succeeded in 2019 to deposit AA2219 material at
97 high deposition rate (1000 cm3 /h) with the aid of solid-state additive deposition pro-
98 cess depending on additive friction stir deposition or MELD. MELD technique sig-
nificantly differs from additive friction stir deposition where now material is extruded
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100 through a hollow rotating tool [11]. This process allows for repairing, coating, and/or
101 building fully dense materials, as it is a highly scalable process, with high deposition
102 rates for aluminum alloys over 1000 cm3 /h. Rivera et al. [18] studied the influence
103 of texture and grain refinement on the mechanical behavior of AA2219; they found

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 4 E. Elfishawy et al.

Fig. 1 Consumable rod

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(20 mm diameter, as
-received die-cast Al–Si

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104 an equiaxed grain morphology in the three orientations. Moreover, while using elec-
105 tron backscatter diffraction (EBSD), they identified a layer-dependent texture in the
106 top of the build with a strong torsional A fiber texture which was transitioning to

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107 weaker textures in the middle and bottom layers. Consequently, the tensile strength
108 increases from the bottom to the top of the deposition which reflects the texture layer
109 dependence. However, the statistically measured hardness showed no significant
110 differences from the top to the bottom of the deposition. Furthermore, mechanical
111 properties were observed to have no orientation dependence for both compression
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and tension specimens tested. Transmission electron microscopy (TEM) illustrated a
lack of θ precipitates in the as-deposited cross section, which is resulting in no pre-
cipitation strengthening [18]. The current study investigates the use of Al–Si cast rod
115 as the consumable rod to produce FSAMed simple parts. The effect of the rotation
116 rate and feed speed on the microstructure evolution and hardness will be investigated.
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117 Experimental Work

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118 Material

119 Consumable rods (picture shown in Fig. 1) of die cast Al–Si of 20 mm diameter and
120 100 mm length have been used as the starting material in the friction stir additive
manufacturing process.
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122 Friction Stir Additive Manufacturing

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123 Friction stir additive manufacturing was conducted using homemade FSW machine
124 [9]. The difference between FSW&FSP [19] and FSAM is that the used tool in FSW&
125 FSP [20] is non-consumable, hard, and wear resistant tool, unlike the soft consumable
126 tool to be used in FSAM. Most of the previous studies use a continuous feeding
127 extruded wire through a hollow non-consumable tool. This study is to investigate
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128 the mechanism of solid-state friction deposition in the vertical alignment using a
AQ1 129 consumable tool to make the additively manufactured parts (AMPs) (Fig. 2).

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 Additive Manufacturing of Aluminum Using Friction Stir Deposition 5

Fig. 2 FSW machine at

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Suez University

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Different parameters were used to investigate the effect of friction stir deposi-
131 tion process parameters on the microstructure of the produced parts. After care-
132 ful optimization of process parameters, the following parameters were investigated:
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133 1200 rpm spindle rotation speed with 3, 4 and 5 mm/min feeding speeds was exam-
134 ined using consumable rod of die-cast Al–Si. All experiments were done at 0° tilt
135 angle.
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136 Characterization

137 The additively manufactured parts (AMP) have been sectioned vertically along the
138 building direction and the longitudinal sections were prepared according to the stan-
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139 dard metallographic procedures of grinding and up to mechanical polishing using

140 0.3 μm alumina suspension and then investigated using the optical microscopy after
141 etching using Keller’s etchant of chemical composition of 25 ml methanol, 25 ml
142 hydrochloric acid, 25 ml nitric acid, and 1 drop hydrofluoric acid.
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143 Results and Discussion

144 Macro-observations
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145 During the process after fixing the consumable bar on the spindle shank and while
146 rotating, the consumable bar is exposed to severe plastic deformation and heat-up
147 due to the friction between the rod and the substrate. That causes the consumable

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Fig. 3 Cylindrical part produced by FSAM at feeding rate of 3 mm/min, and spindle rotational
speed of 1200 rpm. a As additively manufactured part, b longitudinal section of the FSAMed part

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rod tool to soften and deposit on the substrate in a continuous manner as long as the
feeding continues. The material continues to transfer from the consumable rod to the
substrate in the form of well-bonded layer upon layer to finally form an additively
151 manufactured cylinder by solid-state friction deposition. For more understanding of
152 the process, the material of the tool under hydrostatic pressure is plastically deformed
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153 and deposited on the substrate as they were stirred together to metallurgically bond
154 the material to the substrate and the successive layers together as well. This causes
155 the success of producing the AM cylindrical parts with dimensions’ range about 20–
156 35 mm height and 25 mm dia which was built by friction stirring deposition as shown
in Fig. 3a. The friction stir additive manufactured (FSAMed) parts were completely
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158 sound and continuous without any separations between the internal layers along the
159 AM building direction as shown in Fig. 3b so that the number of layers could not be
160 measured internally.
161 A typical section of the AM parts is shown in Fig. 4 which clearly illustrates the
continuity of the process. Moreover, the macrograph assures the sound defect-free
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163 structure of the AM parts.

164 The Consumable Tool Interface

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165 The investigation of the used consumable tool microstructure showed that at the tool
166 tip adjacent to the substrate, the processing surface of the tool has a refined recrys-
167 tallized grains due to severe plastic deformation. The grain size increases gradually
168 going up to reach the base metal coarse grain structure as shown in Fig. 5. This
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169 microstructure shows the effect of friction stirring process on refining and recrystal-
170 lizing the grains and the silicon precipitates. In Fig. 5, on the right hand a macrograph
171 of the tool side section is shown where the processing side is down which faced the
172 substrate and was exposed to the friction. On the left hand, the different structure of

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 Additive Manufacturing of Aluminum Using Friction Stir Deposition 7

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Fig. 4 Optical macrographs of the FSAMed parts (longitudinal section) at spindle rotational speed
of 1200 rpm at feeding rates of a3 mm/min, b 4 mm/min and c 5 mm/min

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Fig. 5 Macro- and micrograph of the used consumable rod (longitudinal section) at feeding speed
of 4 mm/min and spindle rotational speed of 1200 rpm a microstructure of the above area of the
tool near the base microstructure, b the transition zone, c the recrystallized fine structure which was
exposed to friction with the substrate
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 8 E. Elfishawy et al.

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Fig. 6 Macro- and microstructure of Al–Si AMP at feeding rate of 3 mm/min, and spindle rotational
speed of 1200 rpm

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the tool illustrating the effect of the friction on refining the tool tip grains as shown
174 in (c), going up through the tool, the transition zone (b) between the fine structure of
175 the recrystallized tool tip and the base coarse grain structure (a) is shown. The con-
sumable die-cast rod alloy Al–Si has a relatively coarse grain structure as shown in
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177 Fig. 5a, where the silicon is forming the coarse grain boundaries. During friction stir-
178 ring deposition, the silicon precipitates on the grain boundaries were broke into fine
179 particles and redistributed in the plastically deforming aluminum matrix (Fig. 6c).
180 Thermal treatment with severe plastic deformation causes silicon to coalesce and
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181 spheroidize.

182 Additive Manufactured Parts (AMPs) Microstructure

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183 Microstructural examination of the AMPs was carried out using an Olympus upward
184 Microscope. The optical microscopy examination was carried out on long-transverse
185 sections of the cylindrical AMPs. The microstructure investigation of the AMPs
186 showed very fine grain structure as that is produced in the nugget zone of FSW. That’s
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187 why the stirring zone in the FSAM follows the same dynamic recrystallization (DRX)
188 [13, 21]. There are two types of DRX, continuous DRX and discontinuous DRX. The
189 difference between them is that new grains are formed by a gradual increase in the
190 misorientation between the subgrains in case of the continuous DRX. In the case of
191 discontinuous DRX, grains with high-angle grain boundaries form through dynamic
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192 nucleation and growth from a previously deformed microstructure [22]. Previous
193 research works have concluded that aluminum alloys commonly undergo dynamic
194 recovery (DRV) during hot deformation [21]. Another study made by Su et al. on
195 AA7075 has shown that Aluminum alloys in the FSW and FSP will experience

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 Additive Manufacturing of Aluminum Using Friction Stir Deposition 9

different mechanisms such as discontinuous DRX, DRV, and continuous DRX at

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197 different stages of the microstructural evolution [21, 23, 24]. This explained the
198 formation of equiaxed fine grain morphology in the tip of the consumable tool and
199 AMPs microstructure.
200 The microstructure investigation of the AMPs has been studied in different posi-

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201 tions along the specimen. This helps in better understanding of the microstructure.
202 In all feeding rates as shown in Figs. 6, 7, and 8, the microstructure is homoge-
203 neous and nearly the same in any position of the specimen. This fine equiaxed
204 microstructure is the aim which most of AM researchers are seeking for, to ful-
205 fill the industrial requirements of isotropic mechanical properties. The micrographic

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206 study also shows the refined grains and the spheroidal precipitates resulting from
207 dynamic recrystallization.

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Fig. 7 Macro- and microstructure of Al–Si AMP at feeding rate of 4 mm/min, and spindle rotational
speed of 1200 rpm
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Fig. 8 Macro- and microstructure of Al–Si AMP at feeding rate of 5 mm/min, and spindle rotational
speed of 1200 rpm

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 10 E. Elfishawy et al.

Table 1 Hardness values of

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Specimen Rotation Feeding Average

the base Al–Si rod and the
no. speed (rpm) speed hardness
AMPs
(mm/min) (HV)
Base 85.86
1 1200 3 81.08

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2 1200 4 79.84
3 1200 5 82.14

Hardness

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208

209 Bulk hardness measurements were carried on the longitudinal sections of the cylin-
210 drical AMPs using a Vickers hardness tester. The results in Table 1 show the average
211 of 5 readings which were taken on each sample. There were no statistically signifi-
cant differences in hardness measured from the top to the bottom of the deposition.
212

213

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The hardness results showed no significant change of the hardness properties of the
material before and after FSAM. This implies that the grain refining has almost no
effect on the hardness and also the fragmented stable particles also have not affected
216 the hardness of the AMPs.
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217 SEM Analysis

SEM examination of the AMPs revealed significant fragmentations for the inter-
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218

219 metallic particles that were existing in coarse sizes in the base material. This reflects
220 the effect of the stirring process in the fragmentation and distribution of the stable
221 intermetallic particles (Fig. 9).
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Fig. 9 SEM micrographs for the Al–Si AMPs using 1200 rpm and 6 mm/min feeding speed at
different magnifications

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 Additive Manufacturing of Aluminum Using Friction Stir Deposition 11

Conclusion
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222

223 This study investigates the microstructure and mechanical properties of AMPs pro-
224 duced using die-cast Al–Si consumable rod by continuous friction stir deposition
225 process, and the following conclusions can be drawn:

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226 • Al–Si AMPs were successfully produced by friction stir deposition in multiple
227 layers of thickness up to 30 mm without any physical discontinuities or interfa-
228 cial defects between layers. Moreover, the parts are homogenous and continuous
229 without any separation between the layers.
• The current investigation establishes the feasibility of a novel additive manufac-

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230

231 turing technique depending on the high-performance continuous friction stirring

232 process.
233 • The Al–Si AMPs produced in the current work feature several impressive
234 microstructural characteristics such as dynamically recrystallized, ultra-fine grains
with very fine, well-distributed precipitates, and homogeneous and equiaxed
235

236

237

238
microstructure. DP
• The grain structure formed in the AMP is significantly fine grain structure ranging
between 2 and 5 μm relative to the base material grain structure that was coarse
239 grain structure of about 50 μm. In addition, the coarse intermetallic in the cast
240 alloy has been significantly refined and uniformly distributed in the matrix alloy.
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241 Acknowledgements Science and Technology Development Fund is acknowledged for funding
242 this work with grants no. 3926 and 5304.
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243 References

244 1. Khodabakhshi F, Gerlich AP (2018) Potentials and strategies of solid-state additive friction-stir
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245 manufacturing technology: a critical review. J Manuf Process 36(July):77–92

246 2. Yu HZ et al (2018) Non-beam-based metal additive manufacturing enabled by additive friction
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251 structural performance. JOM 67(3):616–621

252 5. Buffa G, Fratini L, Hua J, Shivpuri R (2006) Friction stir welding of tailored blanks:
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257 7. Herzog D, Seyda V, Wycisk E, Emmelmann C (2016) Additive manufacturing of metals. Acta
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9. L. Tonelli et al (2019) “Effect of FSP parameters and tool geometry on microstructure, hardness,
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262 and wear properties of AA7075 with and without reinforcing B4C ceramic particles. Int J Adv
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267 11. Rivera OG et al (2017) Microstructures and mechanical behavior of Inconel 625 fabricated by
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273 14. Karthik GM, Ram GDJ, Kottada RS (2016) Friction deposition of titanium particle reinforced
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 Author Queries
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Chapter 21

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Query Refs. Details Required Author’s response

AQ1 Please check and confirm if the inserted citations of ‘Figs. 2 and
9’ are correct. If not, please suggest an alternate citations. Please
note that figures should be cited sequentially in the text.

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Please correct and return this set
Please use the proof correction marks shown below for all alterations and corrections. If you
wish to return your proof by fax you should ensure that all amendments are written clearly
in dark ink and are made well within the page margins.

Instruction to printer Textual mark Marginal mark

Leave unchanged under matter to remain
Insert in text the matter New matter followed by
indicated in the margin or
Delete through single character, rule or underline
or or
through all characters to be deleted
Substitute character or
through letter or new character or
substitute part of one or
more word(s) through characters new characters
Change to italics under matter to be changed
Change to capitals under matter to be changed
Change to small capitals under matter to be changed
Change to bold type under matter to be changed
Change to bold italic under matter to be changed
Change to lower case Encircle matter to be changed
Change italic to upright type (As above)
Change bold to non-bold type (As above)
or
Insert ‘superior’ character through character or
under character
where required
e.g. or
Insert ‘inferior’ character (As above) over character
e.g.
Insert full stop (As above)
Insert comma (As above)
or and/or
Insert single quotation marks (As above)
or

or and/or
Insert double quotation marks (As above)
or
Insert hyphen (As above)
Start new paragraph
No new paragraph
Transpose
Close up linking characters

Insert or substitute space through character or

between characters or words where required

Reduce space between between characters or

characters or words words affected