Field-assisted friction stir additive manufacturing
A method of forming a metal workpiece is disclosed herein. The method includes applying an electrical current through a feedstock material, applying a vertical axis force to the feedstock material; applying a rotational force to the feedstock material, and producing a metallic component from the feedstock material based on the electric current, the vertical axis force, and the rotational force.
1. A method for forming a metal workpiece, comprising:
applying an electrical current to a feedstock material;
applying a vertical axial force to a first end of the feedstock material, wherein the axial force is provided via a press mechanism;
applying a rotational force to the feedstock material; and
producing a metallic component from a second end of the feedstock material based on the electrical current, the vertical axial force, and the rotational force,
wherein a first end of an electrical current circuit supplying the electrical current is applied to the first end of the feedstock material and a second end of the electrical current circuit is applied to a substrate.
2. The method of claim 1 , wherein the electrical current is at least one of a direct electrical current or an alternating electrical current.
3. The method of claim 1 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is the same as the second material.
4. The method of claim 1 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is different material than the second material.
5. The method of claim 1 , wherein the feedstock material is a metal alloy with a hardness at or above a 4 hardness (Mohs).
6. The method of claim 1 , wherein producing the metallic component from the feedstock material further comprises:
preforming a first deposition process to form a first layer on a substrate; and
preforming a second deposition process to form a second layer over the first layer.
7. The method of claim 6 , wherein the first layer is formed to a first thickness and the second layer is formed to a second thickness.
8. The method of claim 6 , wherein the first deposition process is a stir friction welding process.
9. A system, comprising:
an electric current source;
a force mechanism;
a rotating tool;
a controller; and
a tangible, non-transitory memory configured to communicate with the controller, the tangible, non-transitory memory having instructions stored thereon that, in response to execution by the controller, cause the controller to perform operations comprising:
commanding the electric current source to apply an electrical current to a feedstock material;
commanding the force mechanism to apply a vertical axial force to a first end of the feedstock material, wherein the axial force is provided via a press mechanism;
commanding the rotating tool to apply a rotational force to the feedstock material; and
producing a metallic component from a second end of the feedstock material based on the electrical current, the vertical axial force, and the rotational force,
wherein a first end of an electrical current circuit supplying the electrical current from the electric current source is applied to the first end of the feedstock material and a second end of the electrical current circuit is applied to a substrate on which the metallic component is produced.
10. The system of claim 9 , wherein the electrical current is at least one of a direct electrical current or an alternating electrical current.
11. The system of claim 9 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is the same as the second material.
12. The system of claim 9 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is different material than the second material.
13. The system of claim 9 , wherein the feedstock material is a metal alloy with a hardness at or above a 4 hardness (Mohs).
14. A method of forming a metal workpiece, comprising:
receiving a feedstock material comprising a first material;
applying an electrical current to the feedstock material to heat the feedstock material to a first temperature;
applying a vertical axial force to a first end of the feedstock material, wherein the axial force is provided via a press mechanism;
applying a rotational force to the feedstock material, wherein an application of the vertical axial force and the rotational force causes a second end of the feedstock material to heat to a second temperature, wherein the second temperature is higher than the first temperature; and
producing a metallic component from the second end the feedstock material,
wherein a first end of an electrical current circuit supplying the electrical current from an electric current source is applied to the first end of the feedstock material and a second end of the electrical current circuit is applied to a substrate on which the metallic component is produced.
15. The method of claim 14 , wherein the electrical current is at least one of a direct electrical current or an alternating electrical current.
16. The method of claim 14 , wherein the substrate is comprised of a second material and wherein the first material is the same as the second material.
17. The method of claim 14 , wherein the substrate is comprised of a second material and wherein the first material is different material than the second material.