Friction stir additive manufacturing, which is a solid-state process of additive manufacturing, is to be examined in this work. The material to be used is aluminium alloy 5083-O, which strengthens by grain boundary strengthening and solid solution strengthening mechanism. Five AA5083 layers have been joined using the FSAM process with three variable parameters viz. tool pin profile, spindle speed and feed rate. Layer number will also be considered as a process parameter to understand its effect on mechanical property and microstructure. Temperature and force will be measured for each FSAM pass during the process using a K-type thermocouple and strain-gauge-based force dynamometer, respectively. Conical shape, cylindrical pin with three concave arc grooves and flared pin with three concave arc grooves will be used as the three pin profiles.
Purpose: To develop an understanding of the FSAM process physics based on the thermo-mechanical variables viz. temperature and forces observed during the process under various sets of input process parameters.
Design/Methodology/ Approach: Experimental
Findings: There is strength improvement in the FSAM build zone.
Research Limitations/ implications: The research applicability is limited to non-age hardenable wrought aluminium alloys such as AA5083-O
Originality/ Value: Effect of layer number on the mechanical property and microstructure of the build.
Keywords: Friction stir additive manufacturing, Build layer number, Hardness, Microstructure, AA5083-O