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Fundamental and Applied Studies in Friction Based Consolidation and Extrusion of Finely Divided Metals University of South Carolina/NASA Aeronautics Mission Directorate

Friction extrusion and consolidation was used to produce 2 mm diameter wires that were subsequently used as feedstock for a wire-arc-additive-manufacturing, WAAM, process. The wires were made from aluminum alloy 6061. This is a wire composition which is not commercially available but, as it is a precipitation hardenable alloy, it may be suitable for additive manufacturing of aerospace components or other applications requiring good strength and ductility. The wire was produced at the University of South Carolina and the WAAM process was performed at Cranfield University (UK). Mechanical testing of the structure produced by WAAM indicates good ductility and reasonable strength. Critical issues for better WAAM structures produced from friction extruded wires include optimized wire cleaning and handling and production of wires sufficiently long for use in automated MIG or TIG deposition processes. Overall, feasibility of using friction extrusion to produce small lots of custom or experimental wire compositions has been demonstrated. Further development of the friction extrusion process will enable rapid screening of various high strength alloy wires to produce high value added, high strength, aerospace components with minimum material waste.

Anthony Reynolds, PhD, Sctience PI, University of South Carolina, Columbia

Figures show 2 mm diameter 6061 wire produced by friction extrusion at the University of South Carolina (top) and a wall built from this wire by wire-arcadditive manufacturing at Cranfield University (UK). The wall is 15 mm high.



NASA EPSCoR Stimuli 2014 -15

Maria Domack, NASA Technical Monitor, Langley Research Center

EPSCoR Stimuli 2014-15  

NASA Office of Education’s Aerospace Research & Career Development (ARCD) is pleased to release NASA EPSCoR Stimuli, a collection of univers...

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