Hybrid Wire-Arc Additive Manufacturing and Friction Stir Processing for Manufacturing and Repairing 7075 Aluminum Components - MSC P4876

Materials Sciences LLC (MSC) in partnership with the University of Pittsburgh (PITT) proposes to develop a method to repair Launcher Rail Bodies that meet part strength requirements and enables additive manufacturing for aluminum Al7075-T6 repairs. To mitigate technical risk, MSCÆs significant experience in advanced materials and structural modeling, analysis, and design and the production of launcher rail body components will be paired with PITTÆs experience in AM processing and optimization. The teamÆs extensive knowledge of material development and wide range of repair experience reduce technical risk for this unique method which will be designed to meet strength requirements for aluminum 7075-T6. In order to achieve the desired mechanical performance of AM Al7075 that has never before been realized, the team proposes to employ a hybrid wire-arc DED, friction stir processing (FSP), and milling method to both repair and manufacture Al7075 components.Ā The key innovations of this approach include:Ā i) the hybrid method can refine the grain structure in wire-arc DED deposition, enhancing the material strength/ductility and enabling more precipitation along the grain boundaries via T6 post heat treatment; ii) the method can homogenize the microstructure and heal microcracks/pores in the wire-arc deposits, especially in the heat affected zone (HAZ); iii) the method is implemented as a standalone system which can be employed to perform both repair and manufacture of Al7075 components.Ā The research plan is to conduct process development to minimize porosity and microcracking as well as optimize the material microstructure to attain at least 70% of the tensile properties of conventional Al7075-T6.Ā