Coaxial Wire Feeding-Friction Stir Additive Manufacturing

At present, most studies in the field of Wire-Friction Stir Additive Manufacturing (W-FSAM) adopt the side wire feeding method. However, the side wire feeding method has problems in that the wire feeding tube occupies working space and the tool is prone to clogging. To address this, this study proposes a Coaxial Wire Feeding-Friction Stir Additive Manufacturing (CWF-FSAM) method. The CWF-FSAM device adopts a structure where a fixed shaft is coaxially nested inside the stirring shaft, and the fixed shaft is machined with through-channels along the circumferential direction for wire feeding, which eliminates the limitation of the wire feeding tube. This study elaborates on the structure of the CWF-FSAM device, then uses 6061 aluminum alloy as the deposition material for additive manufacturing, and conducts characterization and analysis on the microstructure and mechanical properties of the deposited components. The results show that the interlayer bonding of the deposited components is dense without defects. The components exhibit uniform and fine equiaxed grains, with the average grain sizes of the top, middle, and bottom parts being 3.52 µm, 3.35 µm, and 4.07 µm, respectively. In terms of mechanical properties, the tensile strengths of the components along the building direction (BD) and longitudinal direction (LD) both reach 70% of that of the base material (BM) wire. The hardness ranges from 36 HV to 42 HV. In addition, closed-loop components were prepared by continuous counterclockwise deposition using the CWF-FSAM device. The tensile strengths of the overlapping area, straight section, and corner were 124.45 MPa, 125.88 MPa, and 126.95 MPa, respectively. The overall performance of the closed-loop components is uniform and stable, which indicates that the CWF-FSAM-deposited components have good mechanical property isotropy.