Research status and development trend of friction stir additive manufacturing technology

Additive friction stir deposition was a new solid phase additive manufacturing technology developed in recent years. This paper briefly described the limitations of the traditional high-energy beam additive manufacturing technology for forming high-performance metal structural parts and the technical advantages of additive friction stir deposition technology. The main types of additive friction stir deposition technologies developed at home and abroad were summarized, including coaxial feed, preset feed, cold spraying compound friction stir, and consumable friction stir tool additive manufacturing, among which the research on bar coaxial feed developed by MELD company was the most advanced. Furthermore, the applications of additive friction stir deposition technology were presented such as in manufacturing and feature addition of lightweight and large structural parts, preparation of gradient materials and coatings, defect repair and new composite materials. Finally, the development trend of additive friction stir deposition technology was prospected.Highlights: (1) In order to solve the application limitation of high energy beam additive manufacturing technology on the lightweight material member, we proposed the additive friction stir deposition which was a new type of solid phase toughening material manufacturing technology, it had no liquid metal forming characteristics in making parts, so it had not forming defects associated with rapid solidification, such as porosity, crack, element segregation, dilution, fine dispersed oxide aggregation and high residual stress, with higher forming efficiency, larger forming size and better mechanical properties.(2) In this paper, by analyzing the process characteristics and application status of additive friction stir deposition, it was concluded that this technology had great application potential in the additive manufacturing of lightweight and large structural parts, the addition of characteristic structures, the preparation of gradient materials and coatings, defect damage repair and the preparation of new composite materials.