Abstract
Friction stir additive manufacturing is a metal additive manufacturing (MAM) technology based on solid-state joining developed from friction stir welding. In this article, a friction-stir side additive manufacturing (FSSAM) process based on a modified common milling machine is proposed as an alternative to existing strip-feed MAM. MAM of 6156 aluminum alloy was performed using the FSSAM process on an aluminum alloy plate substrate. Following initial macroscopic examination and scanning electron microscope analysis of tensile specimen fractures, hardness distribution and tensile properties were evaluated. Finally, theoretical modeling of heat input during the additive manufacturing process was developed. For specimens fabricated via FSSAM under process parameters of 750 rpm tool rotational speed and 37.5 mm/min traverse speed, the tensile strength reached 273.62 MPa. Hardness testing revealed that rotational speed and traverse speed significantly influence hardness curve stability. The most stable hardness profile (averaging 70 HV0.2) was achieved at 50 rpm and 37.5 mm/min. The results indicate that the specimen exhibits optimal mechanical properties when the FSSAM tool is operated at a plunge depth of 2.60 mm, a rotational speed of 950 rpm, and a traverse speed of 37.5 mm/min.