Effects of process parameters on properties of friction stir additive manufactured copper

This article investigated the effects of friction stir additive manufacturing (FSAM) process parameters on the microstructure and mechanical properties of copper. The FSAM tool plunge depth, tilt angle, and rotational and traverse velocities are considered as variables. Material flow, internal defects, hardness, and mechanical properties are analyzed on FSAM samples. The results show that the FSAM of copper is very sensitive to process parameters, and incomplete deposition can happen during FASM with inappropriate process parameters. The microstructure of the printed layer tolerates a thermo-mechanical cycle during the process and reheating after depositing new layers. In the center of the print, an ultra-fine grained zone formed called the re-stirring area. The highest strength printed sample achieved at 3 degrees degree tool tilt, 0.25-mm plunge depth, 2000-rpm rotation, and 16-mm/min traverse speed that has similar to 85-HV hardness and 205-MPa tensile strength.