Innovative Solid-State AM Techniques for Large Aluminum Vertical Lift Component Replacement

The increasing demand for replacement components in aging aircraft has led to the exploration of an innovative manufacturing method utilizing 7000 series aluminum. Traditional forging techniques for component replacement present challenges such as lengthy lead times and logistical complexities. Additive manufacturing (AM) has emerged as a potential solution to streamline the replacement process. However, fusion-based AM of 7000 series aluminum encounters difficulties with solidification cracking, which is similar to issues encountered in traditional welding of the material. To overcome these challenges, alloying elements are typically introduced to the feedstock, which can result in modified material properties. An alternative approach with promising potential is Additive Friction Stir Deposition (AFSD). This method allows for the printing of 7000 series aluminum without the need for alloying elements. Nevertheless, the graphite coating used as a lubricant in the AFSD feedstock has been detected in the final printed parts, leading to unintended alterations in mechanical properties. As a result, the current state of AFSD falls short of achieving one-to-one replacements of traditionally manufactured components made of 7000 series aluminum.