Developing Aerospace High Strength Aluminum AFSD Process for Critical Defense Parts

Additive Friction Stir Deposition (AFSD) is a method of additive manufacturing in which metal rod inputs are spun at high speeds and plastically deformed into uniform layers. By depositing subsequent layers over the initial deposition this technology allows for the printing of 3D structures and large geometries that manufacturers have historically produced through either a casting, rolling, or forging process. By increasing the TRL/MRL of this technology, industry partners will be able to put critical aviation parts into production via additive manufacturing on a larger scale reducing lead times and aircraft-on-ground penalties across multiple programs.

To achieve this ambitious plan ASTRO America, under contract with Army DEVCOM Ground Vehicle Systems Center (GVSC), and in conjunction with the Joint Manufacturing Technology Center (JMTC) at Rock Island Arsenal, has partnered with a large team of university researchers, industry research labs, Army partner organizations, and industry technology specialists to further qualification and the adoption of AFSD. The combination of all our partner organizations puts this project in a unique position to address a range of problems spanning from design to production, non-destructive testing, quality, and standardization, enabling rapid advancement into a low-rate production phase within two to three years.

The next stage of development will be a comprehensive look at 7xxx series high strength aluminum alloys including the development and qualification of materials, machines, and parts to achieve production-ready capability for critical DoD components. In addition to continuing the refinement of AFSD process variables, process monitoring and graphite-free tools, this stage of experiments will delve into the product and process metallurgy and thermal process development necessary to arrive at finished builds which reliably meet the relevant industry standards and certification-ready quality systems.