Laser Metal Deposition (LMD) is an additive manufacturing technique for manufacturing complex near net shaped components. The grain size of the typical deposition microstructure in case of Ti-6Al-4V can range between 100µm-600µm, which is much larger than that of forged-like microstructures. Friction Stir Processing (FSP) has been investigated as a method for surface modification to form refined microstructure at the surface of the Ti-6Al-4V components manufactured from the LMD method. Integration of FSP and LMD can greatly improve the product properties. Friction stir processing of the laser deposited Ti-6Al-4V deposits was performed and optimum processing parameters were obtained using this hybrid process. The microstructure of the nugget regions obtained in the substrate weld, stir over deposit and deposit over stir experiments is presented. A much decreasing grain size was observed in the dilution zone inside the nugget from the stir surface to the bottom of the dilution zone.

Meeting Name

25th Annual International Solid FreeForm Fabrication Symposium (2014: Aug. 4-6, Austin, TX)


Mechanical and Aerospace Engineering

Second Department

Materials Science and Engineering

Research Center/Lab(s)

Intelligent Systems Center


National Science Foundation (U.S.)


This research was supported by the National Science Foundation grants DMI-9871185 and IIP-0637796, the grant from the U.S. Air Force Research Laboratory contract # FA8650-04-C-5704.

The support from Boeing Phantom Works, Product Innovation and Engineering, LLC, Spartan Light Metal Products Inc, Missouri S&T Intelligent Systems Center, and Missouri S&T Manufacturing Engineering Program, is also greatly appreciated.

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

06 Aug 2014