Additive Manufacturing for Powders that Cannot Undergo Liquid State Processing

Advancements in material performance are possible with powder alloys, however many proprietary alloy powders cannot undergo liquid state processing and therefore have limitations in AM manufacturability.  Today, parts can be fabricated with good properties using extrusion, but extruded parts are limited in size and geometry.  Since traditional fusion-based processes are not applicable to these materials, alternative processing methods are needed.  Additive Friction Stir (AFS) is a solid-state additive manufacturing process that allows high-deposition rate AM without melting.  Relatively homogenous wrought microstructures with refined grains have been demonstrated in AFS deposited materials.  Depositions are fully dense and do not require a secondary densification process.  AFS allows powder use for AM of parts, billet fabrication, joining, coating, and repair applications.  This presentation will examine the microstructure and mechanical properties of AFS deposited AL-TM aluminum alloy powders in comparison to extruded parts.