Systems and methods for fabricating a direct metal deposition structure having fully forged structural qualities

1. A method for fabricating a direct metal deposition structure having substantially fully forged structural qualities, said method comprising:

depositing, via a direct metal deposition (DMD) assembly, a DMD layer of melted metallic material onto an existing metallic structure, the existing metallic structure having a microstructure that provides the existing metallic structure with substantially fully forged structural qualities of the respective metal of the existing metallic structure, the DMD layer having a microstructure that provides the DMD layer with non-forged structural qualities, the structural qualities including a durability, a hardness, a ductility, a tensile strength and a shear strength of the metal of the respective existing metallic structure and the DMD layer;

creating, via heat from the deposited melted DMD layer, a DMD affected zone within the existing metallic structure adjacent where the deposited DMD layer has been deposited, the DMD affected zone comprising a portion of the existing metallic structure in which the microstructure has been altered by the heat from the deposited melted DMD layer to have non-forged structural qualities of the metal of the existing metallic structure; and

applying a friction stir process to the deposited DMD layer utilizing a friction stir device such that the deposited DMD layer and at least the DMD affected zone of the existing metallic structure are friction stirred to refine and homogenize the microstructure of the deposited DMD layer and at least the DMD affected zone of the existing metallic structure to produce a non-forged aggregate structure having a microstructure that provides the non-forged aggregate structure with substantially fully forged structural qualities of the respective metal of the existing metallic structure, the aggregate structure comprising the existing metallic structure, including the DMD affected zone and the deposited DMD layer.

2. The method of claim 1 wherein applying the friction stir process to the deposited DMD layer comprises applying the friction stir process to the deposited DMD layer utilizing a selected friction stir tool connectable to the friction stir device, the selected friction stir tool including a tip having a particular geometry and dimensions selected to provide a friction stir zone of a desired depth, width and shape that will include at least a portion of the deposited DMD layer and at least the DMD affected zone of the existing metallic structure.

3. The method of claim 1 , wherein the existing metallic structure comprises a forged metal structure, and depositing the DMD layer onto an existing metallic structure comprises depositing the DMD layer onto the forged metal structure.

4. The method of claim 1 , wherein the existing metallic structure comprises a DMD layer that has previously been friction stirred, and wherein depositing the DMD layer onto an existing metallic structure comprises depositing the DMD layer onto the previously friction stirred DMD layer.

5. A method for fabricating a direct metal deposition structure having substantially fully forged structural qualities, said method comprising:

depositing, via a direct metal deposition (DMD) assembly disposed within a processing cabinet of a direct metal deposition and friction stir system, a layer of melted metallic material onto an existing metallic structure, the existing metallic structure having a microstructure that provides the existing metallic structure with substantially fully forged structural qualities of the metal of the respective existing metallic structure, the DMD layer having a microstructure that provides the DMD layer with non-forged structural qualities, the structural qualities including a durability, a hardness, a ductility, a tensile strength and a shear strength of the metal of the respective existing metallic structure and the DMD layer;

creating, via heat from the deposited melted DMD layer, a DMD affected zone within the existing metallic structure adjacent where the deposited DMD layer has been deposited, the DMD affected zone comprising a portion of the existing metallic structure in which the microstructure has been altered by the heat from the deposited melted DMD layer to have non-forged structural qualities of the metal of the existing metallic structure;

selecting a friction stir tool connectable to a friction stir device disposed within the processing cabinet of the direct metal deposition and friction stir system to have a tip having a selected geometry and dimensions structured to provide a friction stir zone of a selected depth, width and shape that will encompass at least a portion of the deposited DMD layer and at least the DMD affected zone of the existing metallic structure when used to friction stir the deposited DMD layer; and

friction stirring the deposited DMD layer utilizing the selected friction stir tool to refine and homogenize the microstructure of the deposited DMD layer and at least the DMD affected zone of the existing metallic structure encompassed within the friction stir zone to produce a non-forged aggregate structure having a microstructure that provides the non-forged aggregate structure with substantially fully forged structural qualities of the metal of the existing metallic structure, the aggregate structure comprising the existing metallic structure, including the DMD affected zone and the deposited DMD layer.

6. The method of claim 5 , wherein the existing metallic structure comprises a forged metal structure, and depositing the DMD layer onto an existing metallic structure comprises depositing the DMD layer onto the forged metal structure.

7. The method of claim 5 , wherein the existing metallic structure comprises a DMD layer that has previously been friction stirred, and wherein depositing the DMD layer onto an existing metallic structure comprises depositing the DMD layer onto the previously friction stirred DMD layer.

8. The method of claim 5 further comprising, prior to friction stirring the deposited DMD layer, milling a top of the deposited DMD layer to provide a flat top surface on the DMD layer.