Evaluating Stress Corrosion Cracking in AFSD-Processed AA7075 Aluminum Alloy for Aerospace Applications

Additive friction stir deposition (AFSD) has emerged as an attractive solid-state additive manufacturing process due to its ability to improve the mechanical properties of metallic materials while maintaining a very small carbon footprint. This research focuses on the stress corrosion cracking (SCC) susceptibility of AA7075 aluminum alloy processed via AFSD. Microstructural analysis of both the feedstock and post-AFSD AA7075 was conducted to understand the impact of the deposition process. The investigation into SCC involved slow strain-rate tensile (SSRT) testing in a 3.5 wt.% NaCl solution at ambient temperature, employing varying strain rates. Comparative analysis with the feedstock rod elucidated the influence of AFSD on SCC resistance, providing critical insights into the efficacy of AFSD processing in mitigating SCC risks in aerospace applications.