Friction Stir Deposition Innovations

Metal additive manufacturing may be limited by build volumes (i.e., it can be hard to make large parts), post-processing requirements, and upfront costs to buy capital equipment. The two NASA-developed technologies are add-on tools for FSW systems (reducing costs), do not require a printer or print bed, and produce parts with high quality surface finishes. The C-FSD attachment includes a non-rotating block through which the C-FSW rotating pin is threaded, and a containment plate to hold the plasticized metal within the system. In this technique, raw metal feedstock is fed into one end of the non-rotating block, is heated and plasticized by the C-FSW pin, and is driven out the other side of the block. The C-FSW pin is used to join the new material to the pre-existing layer. The B-FSD tool uses a dual-shoulder design to print outward from the edge of the base panel. The B-FSD process uses the same feed system as the C-FSD, but utilizes the bobbin/SR-FSW pin's dual shoulders (i.e., containing the metal on both the top and bottom) enabling more complex structures to be made, and the ability to print varying thickness depositions in a single pass. The Additive C-FSD and B-FSD end effector tools are both at technology readiness level (TRL) 4 (component and/or breadboard validation in laboratory environment) and are available for patent licensing.