Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy

Griffiths, R. Joey; Wilson-Heid, Alexander E.; Linne, Marissa A.; Garza, Eleanna V.; Wright, Arnold; Martin, Aiden A.

doi:10.3390/jmmp8040177

Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy

Journal Article · Wed Aug 14 00:00:00 UTC 2024 · Journal of Manufacturing and Materials Processing

DOI:https://doi.org/10.3390/jmmp8040177· OSTI ID:2429735

Griffiths, R. Joey; Wilson-Heid, Alexander E.; Linne, Marissa A.; Garza, Eleanna V.; ;

Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility and use with lower-temperature metals, such as aluminum; however, there is growing interest in higher-temperature materials, such as titanium and steel alloys. In this work, we explore the deposition of an ultrahigh-temperature refractory material, specifically, a tantalum–tungsten (TaW) alloy. The solid-state nature of AFSD means refractory process temperatures are significantly lower than those for melt-based additive manufacturing techniques; however, they still pose difficult challenges, especially in regards to AFSD tooling. In this study, we perform initial deposition trials of TaW using twin-rod-style AFSD with a high-temperature tungsten–rhenium-based tool. Many challenges arise because of the high temperatures of the process and high mechanical demand on AFSD machine hardware to process the strong refractory alloy. Despite these challenges, successful deposits of the material were produced and characterized. Mechanical testing of the deposited material shows improved yield strength over that of the annealed reference material, and this strengthening is mostly attributed to the refined recrystallized microstructure typical of AFSD. These findings highlight the opportunities and challenges associated with ultrahigh-temperature AFSD, as well as provide some of the first published insights into twin-rod-style AFSD process behaviors.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 2429735

Alternate ID(s):: OSTI ID: 2473637

Report Number(s):: LLNL--JRNL-865732; PII: jmmp8040177

Journal Information:: Journal of Manufacturing and Materials Processing, Journal Name: Journal of Manufacturing and Materials Processing Journal Issue: 4 Vol. 8; ISSN JMMPBJ; ISSN 2504-4494

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Switzerland

Language:: English

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36 MATERIALS SCIENCE
42 ENGINEERING
additive manufacturing
friction stir
mechanical testing
recrystallization
refractory metals
solid state
tantalum

Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy

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