Friction screw extrusion additive manufacturing of an Al-Mg-Si alloy

• DOI: 10.1016/j.addma.2023.103621
• Publication Date: 2023-05-22T15:59:20Z
• Authors: Ton Bor; Marijn de Leede; Freek Deunk; Jesper Lind; Wout Lievestro; Henk-Jan Smit; Rob Ariës; Vishal Dolas; Nick Helthuis; Martin Luckabauer; Remko Akkerman
• Keywords: Volume fraction; Elongation

The Friction Screw Extrusion Additive Manufacturing (FSEAM) process is a newly created for additive manufacturing of low weight-high strength aluminum and magnesium alloys in the solid state which are unsuited many fusion-based approaches. based on rotating threaded tool located within stationary housing that equipped with feeding mechanism. dimensions shape deposited layers can be controlled through dedicated printhead design. This work reports results fabrication rectangular structures composed AA6060 T6 feedstock. study mainly focused influence feed ratio quality, microstructure mechanical properties fabricated builds. ratio, defined as fraction volume material per unit time relative to necessary given cross sectional shape, was varied between 0.995 1.7. Solid builds free from macroscopic defects were at ratios 1.3 above. Tensile tests performed samples interior structure build direction showed values ultimate tensile homogeneous elongation excess 100 MPa 12.5 %, respectively. At close one, formed defects, such macro voids insufficiently bonded areas, caused significant reduction typically below 5 %. average grain size 3 – 4 micrometers all hardness reduced 80 HV about 40 ascribed thermo-mechanical processes taking place during transport feedstock by subsequent deposition. appearance occurrence could explained using descriptive model way distributed underneath Lateral plastic deformation occurred both current layer being built previously layers. Further exploratory FSEAM deposition speed increased 490 mm/min favorable 1.3, corresponding rate 400 cm3/hour, while maintaining good without demonstrating future potential process.