Alternative Title

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.

Meeting Name

27th Annual International Solid Freeform Fabrication Symposium -- An Additive Manufacturing Conference (2016: Aug. 8-10, Austin, TX)


Mechanical and Aerospace Engineering

Second Department

Materials Science and Engineering

Research Center/Lab(s)

Intelligent Systems Center

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

10 Aug 2016