In this work, the effect of processing parameters on the resulting microstructure and mechanical properties of magnesium alloy WE43 processed via Additive Friction Stir Deposition (AFSD), a nascent solid-state additive manufacturing (AM) process, is investigated. In particular, a parameterization study was carried out, using multiple four-layer deposits, to identify a suitable process window for a structural 68-layers bulk WE43 deposition. The parametric study identified an acceptable set of parameters with minimal surface defects and excellent consolidation for the fabrication of a bulk WE43 deposition. Microstructural, tensile, and fatigue life characterization was conducted on the bulk WE43 deposition and compared to commercially available wrought material to elucidate the process-structure-property-performance (PSPP) relationship of the AFSD process. This study shows that the bulk WE43 deposit exhibited a refined homogenous microstructure and a texture shift relative to the wrought material. However, a reduction in hardness and tensile behavior was observed in the as-deposited WE43 compared to the wrought control. Additionally, fatigue specimens extracted from the bulk deposition exhibited a decrease in life in the low-cycle regime but performed comparably to the wrought plate in the high-cycle regime. The outcomes of this study illustrate the potential of the AFSD process in additively manufactured structural load-bearing components made with magnesium alloy WE43 in the as-built condition.

Metal foam is light in weight and exhibits an excellent impact-absorbing capability. Laser forming has emerged as a promising process in shaping metal foam plates into desired geometry. While the feasibility and shaping mechanism has been studied, the effect of the laser forming process on the mechanical properties and the energy-absorbing behavior in particular of the formed foam parts has not been well understood. This study comparatively investigated such effect on as-received and laser-formed closed-cell aluminum alloy foam. In quasi-static compression tests, attention paid to the changes in the elastic region. Imperfections near the laser-irradiated surface were closely examined and used to help elucidate the similarities and differences in as-received and laser-formed specimens. Similarly, from the impact tests, differences in deformation and specific energy absorption were focused on, while relative density distribution and evolution of foam specimens were numerically investigated.