Proposed Hybrid Processes for Part Building using Fusion Welding and Friction Stir Processing

It has been shown that a hybrid laser additive manufacturing and friction stir processing can deposit components with forged-like structures. This paper reports a hybrid fusion welding and friction stir process to create parts with quality structures. Combining traditional fusion welding and friction stir processing techniques for non-weldable aluminum alloys could facilitate the joining of difficult geometries in manufactured parts. This research illustrates mechanical property changes for non-weldable and weldable aluminum alloys. The Vickers hardness, and microhardness in the case of AA5052-H32, tensile strength and corrosion resistance of four processing states: base material, fusion welded material, friction stir welded material, and friction stir processed fusion welded material are studied for AA2024-T351, AA5052-H32, and AA7075- T651. This technology has applications to part building for large parts such as landing gear, and ship hulls; where traditional additive manufacturing processes would be excessively costly and time consuming. By joining larger pieces by such a hybrid process, a near net shape approach can be achieved on a large scale. This technology would remove the need for drilling and fastener use, plausibly increasing the strength of large part joints with complex geometries.