Dynamic Tensile Behavior of Laser-Directed Energy Deposition and Additive Friction Stir-Deposited AerMet 100

Quasi-static and high-rate tensile experiments were used to examine the strain rate sensitivity of laser-directed energy deposition (L-DED)- and additive friction stir deposition (AFSD)-formed AerMet 100 ultrahigh-strength steel-additive manufactured builds. Electron backscattered diffraction (EBSD) revealed similar as-deposited grain sizes between the two AM processes at approximately 24 μm and 17 μm for the L-DED and AFSD samples, respectively. The strain hardening rate, θ, revealed little change in the overall hardening observed in the L-DED and AFSD materials, with a consistent hardening in the quasi-static samples and three identifiable regions in that of the high-rate tested materials. The L-DED deposited materials displayed average ultimate tensile strength values of 1835 and 2902 MPa for the 0.001 s⁻¹ and 2500 s⁻¹ strain rates, respectively and the AFSD deposited materials displayed ultimate tensile strength values of 1928 and 3080 MPa for the 0.001 s⁻¹ and 2500 s⁻¹ strain rates, respectively. Overall, the strength for both processes displayed a positive strain rate sensitivity, with increases in strength of ~1000 MPa for both processes. Fractography revealed significant solidification voids in the laser DED material and poor layer adhesion in the AFSD material.