Friction Stir Deposition Innovations

About this technology

Overview

Innovators at the NASA Marshall Space Flight Center have developed two new friction stir deposition (FSD) add-on tools that allow a conventional friction stir welding (C-FSW) system to be reversibly adapted for deposition within minutes. Both FSD end effectors use the rotating pin of the FSW tool to heat and plasticly deform metal feedstock for solid-state additive processes. The first tool—Conventional Friction Stir Deposition (C-FSD)—allows for layer-by-layer addition of extruded metal to an existing part using a C-FSW system plus a side-loading metal bar feeder device and containment block. The exit shape of the containment sets the final geometry of the part, enabling complex shapes (e.g., domes, barrels) to be deposited directly on a substrate (e.g., stiffeners to panels). The second tool—Bobbin Friction Stir Deposition (B-FSD)—makes use of a self-reacting tool design to contain the metal on two sides with the filler material fed between the shoulders. When paired with an FSW machine with a Self-Reacting Friction Stir Weld (SR-FSW) adjustable pin axis, continuously varying thickness parts are printable, as well as free-forming printing of complex curvatures.