Large-Scale Fabrication of Ultrafine-Grained, Functionally-Graded Mg Armor

Additive friction stir (AFS) is a wrought metal deposition process capable of consolidating and depositing advanced metallic materials. In this Phase II effort, AFS will be used to fabricate both plates and complex parts from ultra-fine grained magnesium powders. A detailed process/structure/property relationship study will be performed prior to fabricating the project deliverables to understand the interplay between the AFS process parameters and the final part performance. The Phase II deliverables will be among the largest additively fabricated parts made to date by any process. It is expected that Aeroprobe will also demonstrate the highest volumetric deposition rate for any additive manufacturing process during the fabrication of the deliverables.