Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Joshua Kincaid; Ross Zameroski; Elijah Charles; Timothy No; John Bohling; Brett Compton; Tony Schmitz

doi:10.1016/j.mfglet.2023.08.021

Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Joshua Kincaid, Ross Zameroski, Elijah Charles, Timothy No, John Bohling, Brett Compton, Tony Schmitz

Advanced Machining and Machine Tools Res

Research output: Contribution to journal › Article › peer-review

4 Scopus citations

Abstract

Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

Original language	English
Pages (from-to)	549-556
Number of pages	8
Journal	Manufacturing Letters
Volume	35
DOIs	https://doi.org/10.1016/j.mfglet.2023.08.021
State	Published - Aug 2023

Funding

This work was partially supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (AMO), under contract DE-AC05-00OR22725. The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). The authors would also like to acknowledge support from the NSF Engineering Research Center for Hybrid Autonomous Manufacturing Moving from Evolution to Revolution (ERC‐HAMMER) under Award Number EEC-2133630. This work was partially supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE) , Advanced Manufacturing Office (AMO) , under contract DE-AC05-00OR22725. The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). The authors would also like to acknowledge support from the NSF Engineering Research Center for Hybrid Autonomous Manufacturing Moving from Evolution to Revolution (ERC‐HAMMER) under Award Number EEC-2133630.

Keywords

Additive friction stir deposition
Hybrid manufacturing
Machining
Structured light scanning

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1016/j.mfglet.2023.08.021

Cite this

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title = "Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis",

abstract = "Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.",

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author = "Joshua Kincaid and Ross Zameroski and Elijah Charles and Timothy No and John Bohling and Brett Compton and Tony Schmitz",

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AU - Kincaid, Joshua

AU - Zameroski, Ross

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AU - No, Timothy

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AU - Compton, Brett

AU - Schmitz, Tony

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AB - Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

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Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Abstract

Funding

Keywords

UN SDGs

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