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Multi-track multi-layer friction stir additive manufacturing of AA6061-T6 alloy

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Abstract

Friction stir additive manufacturing (FSAM) is a solid-state sheet-based metal additive manufacturing (MAM) process that utilizes the classical friction stir welding (FSW) process to join the layers. So far, FSAM has been explored for fabricating thin to thick metallic walls. However, to realize large-scale defect-free dense structures, FSAM demands multiple welding tracks in each layer with a suitable overlap. Therefore, this work investigates the effect of overlapping percentages (0%, 25%, 50%, and 75%) in joining two layers of AA6061-T6 alloy by a concave shouldered tool and a cylindrical taper pin. The multi-track FSAM strategy is incorporated to join the two layers with a raster pattern toolpath. The joined layer's cross-sectional micrographs showed the absence of the half-ellipse-shaped banded patterns and a high degree of plasticized material mixing with an increase in overlapping percentage. It has been noticed that the successive overlapping weld tracks act as a post-heat treatment process for pre-scanned tracks, leading to more heat exposure time and grain re-growth. High magnification images and energy dispersion spectroscopy (EDS) revealed the homogeneous distribution of secondary precipitates into the samples prepared by 50% overlap, resulting in relatively higher tensile strength and uniform hardness. As 50% overlap exhibited better mechanical and microstructural properties, it has been further implemented as a toolpath stepover to join multiple sheets of AA6061-T6 material to create a block. The outcomes showed a dense microstructure in the processed zones and good interlayer bonding with increased tensile strength (maximum UTS 258 MPa) and hardness (maximum value 102 HV0.1) along the building direction. Moreover, a spur gear has been realized by machining from the block created by multi-layered multi-track FSAM.

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Acknowledgements

We acknowledge Technology Innovation Hub (TIH), IIT Guwahati to provide experimental facilities. We also acknowledge Department of Science and Technology (DST), New Delhi, India, for financial support for project No. SR/FST/ET-II/2017/111 (C) under Fund for Improvement of S&T Infrastructure in Universities and Higher Educational Institutions (FIST) Program.

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  1. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, India

    Ankan Das, Tanmoy Medhi, Sajan Kapil & Pankaj Biswas

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  1. Ankan Das
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Das, A., Medhi, T., Kapil, S. et al. Multi-track multi-layer friction stir additive manufacturing of AA6061-T6 alloy. Prog Addit Manuf (2023). https://doi.org/10.1007/s40964-023-00485-w

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