Use of friction surfacing for additive manufacturing

In this work, we explore the possibility of utilizing friction surfacing, an emerging solid-state surface coating process, for layer-by-layer manufacture of three-dimensional metallic parts. One possibility in this regard (single-track friction surfacing) is to utilize friction surfacing for depositing a track or layer of material (sufficiently wide to cover the entire layer area), which is subsequently shaped to its corresponding slice counter using CNC machining. Another possibility (multi-track friction surfacing) is to generate a layer from multiple overlapping tracks of friction surfaced material, which is subsequently shaped as required using CNC machining. In the current work, sound multi-layered deposits in various ferrous materials were realized using friction surfacing in both single-and multi-track approaches. Samples with fully enclosed internal cavities and those consisting of different materials in different layers were also successfully produced. The deposits showed fine-grain wrought microstructures with excellent bonding between individual layers and tracks. Basic mechanical properties of these deposits were found to be at par with their standard processed wrought counterparts. Overall, the current work shows that it is possible to develop a uniquely capable new additive manufacturing process based on friction surfacing. © 2013 Taylor & Francis Group, LLC.