Elucidating the Effects of Material Flow from Deposition Offset on AFSD Repair of AA7050

In this work, the effects of tool bias as a processing parameter on an additive friction stir deposition repair of AA7050-T7451 plates were investigated. In this study, the asymmetrical material flow effect was assessed by subjecting a machined groove plate to different tool biases during the AFSD process. The tool bias effectiveness on repairs was quantified through mechanical testing and destructive and non-destructive evaluation. Monotonic tensile tests conducted in parallel with a digital image correlation method captured the mechanical performance of the repairs and the local strain effects of the heat-affected zone. X-ray computed tomography images of the different tool bias repairs were analyzed for any voids or defects to measure the overall bonding effectiveness. The results suggest that the advancing side tool bias had adequate bonding with the substrate, which yielded improved mechanical performance compared to the centered and retreating side depositions.