Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075

Peter C. Metz; Lauren Miller; Joshua Kincaid; Elijah Charles; Andrew T. Wood; Zachary C. Sims; Sean Drewry; Austin Houston; Jeffrey R. Bunn; Brett Compton; Tony Schmitz; Eric A. Lass; Dayakar Penumadu; Katharine Page

doi:10.1016/j.matchar.2025.115600

Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075

Peter C. Metz, Lauren Miller, Joshua Kincaid, Elijah Charles, Andrew T. Wood, Zachary C. Sims, Sean Drewry, Austin Houston, Jeffrey R. Bunn, Brett Compton, Tony Schmitz, Eric A. Lass, Dayakar Penumadu, Katharine Page

Materials Engineering

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

Abstract

Aluminum 7075-T651 was printed by additive friction stir deposition (AFSD) onto 7075-T651 substrate with one-directional passes to form a ∼190 mm wall ∼27 mm in height. Neutron residual stress mapping of the as-printed sample was performed in the longitudinal (LD), transverse (TD), and normal (ND) directions of the build at the longitudinal midplane of the wall with 6 mm LD x 3 mm TD x 3 mm ND voxels. These data were contextualized with microhardness and plastometry mapping, powder X-ray diffraction, electron backscatter diffraction, and scanning transmission electron microscopy. Peak tensile stresses were observed in the base plate 4–5 mm below the base plate-AFSD interface with maximum values of 168 ± 20 MPa LD, 152 ± 16 MPa TD, and 129 ± 16 MPa ND. Peak compressive stresses were located in the deposit, with maximum values −63 ± 19 MPa LD, −39 ± 16 MPa TD, and −67 ± 16 MPa. Gaussian process regression was used to estimate the strength and residual stress values at congruent points throughout the analysis plane. The region of peak residual tensile stress was found to reach 32% of the von Mises yield criterion. The spatial distribution of hardness and strength in the part was found to be independent of grain size effects (d₅₀ ∼ 1μm) but to correlate with the spatial distribution of work hardening, solution strengthening, and precipitation strengthening, reaching an apparent steady state 15 mm below the final AFSD surface.

Original language	English
Article number	115600
Journal	Materials Characterization
Volume	229
DOIs	https://doi.org/10.1016/j.matchar.2025.115600
State	Published - Nov 2025

Funding

This material is based upon work supported by DEVCOM Army Research Laboratory Cooperative Agreement W911NF21200. STEM work (A.H.) is supported by the U.S. Department of Energy, Office of Science, Basic Energy Sciences, Materials Sciences and Engineering Division. A portion of this research used resources at the High Flux isotope Reactor a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. The beam time was allocated to the HIDRA (HB-2B) instrument on proposal number IPTS-31525. X-ray diffraction and electron microscopy was performed using facilities of the Institute for Advanced Materials and Manufacturing at The University of Tennessee, Knoxville. The authors also acknowledge Paris Cornwell (ORNL, NSD) for assistance in conducting the neutron scattering measurements, and Ben Wing and Cole Franz (UTK, MSE) for their critique of this paper. This work makes use of F. Crameri's perceptually uniform color map library. [97] This material is based upon work supported by DEVCOM Army Research Laboratory Cooperative Agreement W911NF21200. STEM work (A.H.) is supported by the U.S. Department of Energy, Office of Science, Basic Energy Sciences, Materials Sciences and Engineering Division. A portion of this research used resources at the High Flux isotope Reactor a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. The beam time was allocated to the HIDRA (HB-2B) instrument on proposal number IPTS-31525. X-ray diffraction and electron microscopy was performed using facilities of the Institute for Advanced Materials and Manufacturing at The University of Tennessee, Knoxville. The authors also acknowledge Paris Cornwell (ORNL, NSD) for assistance in conducting the neutron scattering measurements, and Ben Wing and Cole Franz (UTK, MSE) for their critique of this paper. This work makes use of F. Crameri’s perceptually uniform color map library. [97]

Keywords

Additive friction stir deposition
Aluminum alloy 7075
Gaussian process regression
Neutron residual stress
Profilometry-based indentation plastometry

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10.1016/j.matchar.2025.115600

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Metz, P. C., Miller, L., Kincaid, J., Charles, E., Wood, A. T., Sims, Z. C., Drewry, S., Houston, A., Bunn, J. R., Compton, B., Schmitz, T., Lass, E. A., Penumadu, D., & Page, K. (2025). Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075. Materials Characterization, 229, Article 115600. https://doi.org/10.1016/j.matchar.2025.115600

@article{4be803d5ed4a4409b7c41b8696f65e45,

title = "Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075",

abstract = "Aluminum 7075-T651 was printed by additive friction stir deposition (AFSD) onto 7075-T651 substrate with one-directional passes to form a ∼190 mm wall ∼27 mm in height. Neutron residual stress mapping of the as-printed sample was performed in the longitudinal (LD), transverse (TD), and normal (ND) directions of the build at the longitudinal midplane of the wall with 6 mm LD x 3 mm TD x 3 mm ND voxels. These data were contextualized with microhardness and plastometry mapping, powder X-ray diffraction, electron backscatter diffraction, and scanning transmission electron microscopy. Peak tensile stresses were observed in the base plate 4–5 mm below the base plate-AFSD interface with maximum values of 168 ± 20 MPa LD, 152 ± 16 MPa TD, and 129 ± 16 MPa ND. Peak compressive stresses were located in the deposit, with maximum values −63 ± 19 MPa LD, −39 ± 16 MPa TD, and −67 ± 16 MPa. Gaussian process regression was used to estimate the strength and residual stress values at congruent points throughout the analysis plane. The region of peak residual tensile stress was found to reach 32\% of the von Mises yield criterion. The spatial distribution of hardness and strength in the part was found to be independent of grain size effects (d50 ∼ 1μm) but to correlate with the spatial distribution of work hardening, solution strengthening, and precipitation strengthening, reaching an apparent steady state 15 mm below the final AFSD surface.",

keywords = "Additive friction stir deposition, Aluminum alloy 7075, Gaussian process regression, Neutron residual stress, Profilometry-based indentation plastometry",

author = "Metz, \{Peter C.\} and Lauren Miller and Joshua Kincaid and Elijah Charles and Wood, \{Andrew T.\} and Sims, \{Zachary C.\} and Sean Drewry and Austin Houston and Bunn, \{Jeffrey R.\} and Brett Compton and Tony Schmitz and Lass, \{Eric A.\} and Dayakar Penumadu and Katharine Page",

note = "Publisher Copyright: {\textcopyright} 2025",

year = "2025",

month = nov,

doi = "10.1016/j.matchar.2025.115600",

language = "English",

volume = "229",

journal = "Materials Characterization",

issn = "1044-5803",

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Metz, PC, Miller, L, Kincaid, J, Charles, E, Wood, AT, Sims, ZC, Drewry, S, Houston, A, Bunn, JR, Compton, B, Schmitz, T, Lass, EA, Penumadu, D & Page, K 2025, 'Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075', Materials Characterization, vol. 229, 115600. https://doi.org/10.1016/j.matchar.2025.115600

TY - JOUR

T1 - Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075

AU - Metz, Peter C.

AU - Miller, Lauren

AU - Kincaid, Joshua

AU - Charles, Elijah

AU - Wood, Andrew T.

AU - Sims, Zachary C.

AU - Drewry, Sean

AU - Houston, Austin

AU - Bunn, Jeffrey R.

AU - Compton, Brett

AU - Schmitz, Tony

AU - Lass, Eric A.

AU - Penumadu, Dayakar

AU - Page, Katharine

PY - 2025/11

Y1 - 2025/11

N2 - Aluminum 7075-T651 was printed by additive friction stir deposition (AFSD) onto 7075-T651 substrate with one-directional passes to form a ∼190 mm wall ∼27 mm in height. Neutron residual stress mapping of the as-printed sample was performed in the longitudinal (LD), transverse (TD), and normal (ND) directions of the build at the longitudinal midplane of the wall with 6 mm LD x 3 mm TD x 3 mm ND voxels. These data were contextualized with microhardness and plastometry mapping, powder X-ray diffraction, electron backscatter diffraction, and scanning transmission electron microscopy. Peak tensile stresses were observed in the base plate 4–5 mm below the base plate-AFSD interface with maximum values of 168 ± 20 MPa LD, 152 ± 16 MPa TD, and 129 ± 16 MPa ND. Peak compressive stresses were located in the deposit, with maximum values −63 ± 19 MPa LD, −39 ± 16 MPa TD, and −67 ± 16 MPa. Gaussian process regression was used to estimate the strength and residual stress values at congruent points throughout the analysis plane. The region of peak residual tensile stress was found to reach 32% of the von Mises yield criterion. The spatial distribution of hardness and strength in the part was found to be independent of grain size effects (d50 ∼ 1μm) but to correlate with the spatial distribution of work hardening, solution strengthening, and precipitation strengthening, reaching an apparent steady state 15 mm below the final AFSD surface.

AB - Aluminum 7075-T651 was printed by additive friction stir deposition (AFSD) onto 7075-T651 substrate with one-directional passes to form a ∼190 mm wall ∼27 mm in height. Neutron residual stress mapping of the as-printed sample was performed in the longitudinal (LD), transverse (TD), and normal (ND) directions of the build at the longitudinal midplane of the wall with 6 mm LD x 3 mm TD x 3 mm ND voxels. These data were contextualized with microhardness and plastometry mapping, powder X-ray diffraction, electron backscatter diffraction, and scanning transmission electron microscopy. Peak tensile stresses were observed in the base plate 4–5 mm below the base plate-AFSD interface with maximum values of 168 ± 20 MPa LD, 152 ± 16 MPa TD, and 129 ± 16 MPa ND. Peak compressive stresses were located in the deposit, with maximum values −63 ± 19 MPa LD, −39 ± 16 MPa TD, and −67 ± 16 MPa. Gaussian process regression was used to estimate the strength and residual stress values at congruent points throughout the analysis plane. The region of peak residual tensile stress was found to reach 32% of the von Mises yield criterion. The spatial distribution of hardness and strength in the part was found to be independent of grain size effects (d50 ∼ 1μm) but to correlate with the spatial distribution of work hardening, solution strengthening, and precipitation strengthening, reaching an apparent steady state 15 mm below the final AFSD surface.

KW - Additive friction stir deposition

KW - Aluminum alloy 7075

KW - Gaussian process regression

KW - Neutron residual stress

KW - Profilometry-based indentation plastometry

UR - https://www.scopus.com/pages/publications/105017971232

U2 - 10.1016/j.matchar.2025.115600

DO - 10.1016/j.matchar.2025.115600

M3 - Article

AN - SCOPUS:105017971232

SN - 1044-5803

VL - 229

JO - Materials Characterization

JF - Materials Characterization

M1 - 115600

ER -

Through-thickness microstructure and residual stress distributions in additive friction stir deposited Aluminum 7075

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