Paul G. Allison¹, J. Brian Jordon¹, Luke Brewer¹, Kevin Doherty²; ¹University of Alabama, ²US Army Research Lab

Additive Friction Stir-Deposition (AFS-D) provides a rapid, flexible, and robust metal recycling option that may be applied to manufacture large-scale multi-material components and/or repair damaged structures (i.e. vehicles, armor systems, etc.) while in-theatre thus reducing the associated lead time. This presentation summarizes an experimental and computational investigation on the solid-phase processing of two waste streams: (1) manufacturing chips and (2) field-damaged stacked strips via AFS-D. X-ray Computed Tomography (CT) analyses shows fully-dense depositions while isotropic mechanical behavior is observed in large test articles. Furthermore, the in-depth experimental datasets characterizing microstructure, residual stresses, and mechanical performance are being used to develop multiscale computational models for predicting material performance. The fundamental understanding compiled on this study could serve as the groundwork to transition AFS-D to a mobile and economical manufacturing platform.