Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining

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

doi:10.1007/978-3-031-22661-8_1

Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining

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

Advanced Machining and Machine Tools Res

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

2 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
Title of host publication	Friction Stir Welding and Processing XII
Editors	Yuri Hovanski, Yutaka Sato, Piyush Upadhyay, Anton A. Naumov, Nilesh Kumar
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	3-13
Number of pages	11
ISBN (Print)	9783031226601
DOIs	https://doi.org/10.1007/978-3-031-22661-8_1
State	Published - 2023
Event	12th Symposium on Friction Stir Welding and Processing, held at the TMS Annual Meeting and Exhibition, TMS 2023 - San Diego, United States Duration: Mar 19 2023 → Mar 23 2023

Publication series

Name	Minerals, Metals and Materials Series
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	12th Symposium on Friction Stir Welding and Processing, held at the TMS Annual Meeting and Exhibition, TMS 2023
Country/Territory	United States
City	San Diego
Period	03/19/23 → 03/23/23

Keywords

Additive friction stir deposition
Hybrid manufacturing
Machining
Microstructure
Structured light scanning

UN SDGs

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

Access to Document

10.1007/978-3-031-22661-8_1

Cite this

Kincaid, J., Zameroski, R., No, T., Bohling, J., Compton, B., & Schmitz, T. (2023). Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining. In Y. Hovanski, Y. Sato, P. Upadhyay, A. A. Naumov, & N. Kumar (Eds.), Friction Stir Welding and Processing XII (pp. 3-13). (Minerals, Metals and Materials Series). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-031-22661-8_1

Kincaid, Joshua ; Zameroski, Ross ; No, Timothy et al. / Hybrid Manufacturing : Combining Additive Friction Stir Deposition, Metrology, and Machining. Friction Stir Welding and Processing XII. editor / Yuri Hovanski ; Yutaka Sato ; Piyush Upadhyay ; Anton A. Naumov ; Nilesh Kumar. Springer Science and Business Media Deutschland GmbH, 2023. pp. 3-13 (Minerals, Metals and Materials Series).

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title = "Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining",

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.",

keywords = "Additive friction stir deposition, Hybrid manufacturing, Machining, Microstructure, Structured light scanning",

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

note = "Publisher Copyright: {\textcopyright} 2023, The Minerals, Metals & Materials Society.; 12th Symposium on Friction Stir Welding and Processing, held at the TMS Annual Meeting and Exhibition, TMS 2023 ; Conference date: 19-03-2023 Through 23-03-2023",

year = "2023",

doi = "10.1007/978-3-031-22661-8_1",

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isbn = "9783031226601",

series = "Minerals, Metals and Materials Series",

publisher = "Springer Science and Business Media Deutschland GmbH",

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Kincaid, J, Zameroski, R, No, T, Bohling, J, Compton, B & Schmitz, T 2023, Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining. in Y Hovanski, Y Sato, P Upadhyay, AA Naumov & N Kumar (eds), Friction Stir Welding and Processing XII. Minerals, Metals and Materials Series, Springer Science and Business Media Deutschland GmbH, pp. 3-13, 12th Symposium on Friction Stir Welding and Processing, held at the TMS Annual Meeting and Exhibition, TMS 2023, San Diego, United States, 03/19/23. https://doi.org/10.1007/978-3-031-22661-8_1

Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining. / Kincaid, Joshua; Zameroski, Ross; No, Timothy et al.
Friction Stir Welding and Processing XII. ed. / Yuri Hovanski; Yutaka Sato; Piyush Upadhyay; Anton A. Naumov; Nilesh Kumar. Springer Science and Business Media Deutschland GmbH, 2023. p. 3-13 (Minerals, Metals and Materials Series).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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T1 - Hybrid Manufacturing

T2 - 12th Symposium on Friction Stir Welding and Processing, held at the TMS Annual Meeting and Exhibition, TMS 2023

AU - Kincaid, Joshua

AU - Zameroski, Ross

AU - No, Timothy

AU - Bohling, John

AU - Compton, Brett

AU - Schmitz, Tony

PY - 2023

Y1 - 2023

N2 - 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.

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.

KW - Additive friction stir deposition

KW - Hybrid manufacturing

KW - Machining

KW - Microstructure

KW - Structured light scanning

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DO - 10.1007/978-3-031-22661-8_1

M3 - Conference contribution

AN - SCOPUS:85151051946

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T3 - Minerals, Metals and Materials Series

SP - 3

EP - 13

BT - Friction Stir Welding and Processing XII

A2 - Hovanski, Yuri

A2 - Sato, Yutaka

A2 - Upadhyay, Piyush

A2 - Naumov, Anton A.

A2 - Kumar, Nilesh

PB - Springer Science and Business Media Deutschland GmbH

Y2 - 19 March 2023 through 23 March 2023

ER -

Kincaid J, Zameroski R, No T, Bohling J, Compton B, Schmitz T. Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining. In Hovanski Y, Sato Y, Upadhyay P, Naumov AA, Kumar N, editors, Friction Stir Welding and Processing XII. Springer Science and Business Media Deutschland GmbH. 2023. p. 3-13. (Minerals, Metals and Materials Series). doi: 10.1007/978-3-031-22661-8_1

Hybrid Manufacturing: Combining Additive Friction Stir Deposition, Metrology, and Machining

Abstract

Publication series

Conference

Keywords

UN SDGs

Access to Document

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