Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy
Abstract
:1. Introduction
2. Materials and Methods
2.1. Twin-Rod Additive Friction Stir Deposition
2.2. Material Characterization
3. Results
3.1. Deposition Behavior
3.2. Microstructural Characterization
3.3. Physical Characterization
4. Discussion
4.1. Feed Material Heating during Twin-Rod AFSD
4.2. High-Temperature Twin-Rod AFSD Behavior
4.3. Microstructural Evolution during AFSD of Ta2.5W
4.4. Mechanical Behavior of AFSD Ta2.5W
4.5. Opportunities and Challenges in Refractory Twin-Rod AFSD
5. Conclusions
- Twin-rod AFSD was found to be very capable for heating and spreading the feed material; however, a skating behavior dominated the trials because of poor adhesion with the substrate. The skating behavior could not be reliably overcome by adjusting the AFSD process variables, implying modifications to the setup will be required to promote substrate adhesion in future research;
- The microstructures of the deposits were found to consist of multiple distinct regions tied to the deformation and bonding of the two feed rods. Some porosity and interfaces existed where the two rods had not fully bonded together. The grain refinement of the material occurred via continuous dynamic recrystallization;
- The refined microstructures of the AFSD deposits resulted in higher yield strengths (a 28% average increase) and typically lower elongations at failure. The strengthening is attributed to a refined grain structure and the presence of residual dislocations, while the inconsistent properties are attributed to sample defects, which are not expected to be as prevalent in deposits produced using more sustained depositions.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Voxel Size (µm) | Voltage | Current | Power | Filter Material and Thickness (mm) | X-ray Source-to-Detector Distance (mm) | Exposure Time (ms) | Number of Projections | Number of Frames Averaged |
---|---|---|---|---|---|---|---|---|
22 | 220 | 100 | 22 | Sn, 1 | 1180 | 4000 | 1120 | 2 |
Trial No. | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
---|---|---|---|---|---|---|---|---|---|---|
Tool Rotation Rate (rev/min) | 500 | 500 | 800 | 500 | 500 | 500 | 500 | 450 | 450 | 500 |
Tool Traverse Rate (mm/min) | 100 | 100 | 50 | 0 | 0 | 12.5 | 12.5 | 12.5 | 18 | 24 |
Material Feed Rate (mm/min) | 38 | 38 | 19 | 0 | 0 | 2 | 2 | 3 | 3 | 3 |
Average Spindle Torque (Nm) | n/a | n/a | 60 | 20 | 20 | 50 | 75 | 85 | 75 | 100 |
Peak Spindle Torque (Nm) | 380* | 270 | 250 | 30 | 42 | 73 | 100 | 300 * | 100 | 300 * |
Average Actuator Load (kN) | n/a ** | n/a ** | 20 | 1 | 2.5 | 5 | 4 | 4.8 | 5 | 7 |
Peak Actuator Load (kN) | 16 | 14 | 30 | 6 | 4.8 | 7 | 10.5 | 14 | 8 | 18 |
Outcome | Rapid Overload No Adhesion | Rapid Overload No Adhesion | Partial Deposition and Tool Jam | No Adhesion | No Adhesion | Skating and Tool Jam | Skating | Skating and Deposition | Skating | Skating, Deposition, and Tool Jam |
Upper Region | Lower Region | ||||
---|---|---|---|---|---|
S1 | S2 | S3 | S1 | S2 | S3 |
0° | 45° ± 120°/240° | 0° | 7° | 8° ± 120°/240° | 15° |
Region | Average Measured | ||||
---|---|---|---|---|---|
Upper | 194 | 99.7 | 63.1 | 356.8 | 371.5 |
Lower | 194 | 115.2 | 64.8 | 374.0 |
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Griffiths, R.J.; Wilson-Heid, A.E.; Linne, M.A.; Garza, E.V.; Wright, A.; Martin, A.A. Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy. J. Manuf. Mater. Process. 2024, 8, 177. https://doi.org/10.3390/jmmp8040177
Griffiths RJ, Wilson-Heid AE, Linne MA, Garza EV, Wright A, Martin AA. Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy. Journal of Manufacturing and Materials Processing. 2024; 8(4):177. https://doi.org/10.3390/jmmp8040177
Chicago/Turabian StyleGriffiths, R. Joey, Alexander E. Wilson-Heid, Marissa A. Linne, Eleanna V. Garza, Arnold Wright, and Aiden A. Martin. 2024. "Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy" Journal of Manufacturing and Materials Processing 8, no. 4: 177. https://doi.org/10.3390/jmmp8040177