Advanced Manufacturing Technologies: Friction Stir Welding and Additive Manufacturing of Metals

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 518

Special Issue Editors


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Guest Editor
Department of Materials Science and Engineering, Taiyuan University of Technology, Taiyuan 030024, China
Interests: welding; additive manufacturing; fracture; corrosion
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Taiyuan University of Technology, Taiyuan 030024, China
Interests: welding; additive manufacturing; fatigue fracture

Special Issue Information

Dear Colleagues,

Since the invention of friction stir welding (FSW) in 1991, this technology has demonstrated significant advantages in joining low-melting-point materials and has driven innovations in aerospace, automotive, shipbuilding, and railway industries, among others. Based on the principles of FSW, a novel solid-state forming process—friction stir additive manufacturing—has been developed, becoming a research hot spot. This technology shows enormous potential in producing high-precision and high-performance parts, enabling the creation of complex geometries which traditional manufacturing methods cannot achieve while significantly reducing material waste. The development of metal friction stir welding and friction stir additive manufacturing technologies not only improves the accuracy and quality of metal components but also enhances production efficiency and reduces costs. Friction stir welding and derived additive manufacturing technologies play a crucial role in driving modern manufacturing toward efficiency, intelligence, and sustainability, with enormous application potential.

This Special Issue aims to capture the latest trends and developments in manufacturing technologies related to friction stir welding and friction stir additive manufacturing. We invite researchers from around the world to submit original research papers, review articles, and short communications to explore the latest advancements in friction stir welding/additive manufacturing technologies. We are particularly interested in papers that provide new insights, innovative approaches, and significant advancements in the applications of these technologies.

Potential topics include but are not limited to the following:

  1. Application of metal friction stir welding/additive manufacturing technologies in dissimilar materials and high-performance alloys;
  2. Development of tool design in friction stir-related manufacturing processes;
  3. Multi-scale modeling and simulation of the metal friction stir welding/additive manufacturing process;
  4. Comparative study of metal friction stir welding/additive manufacturing technologies and traditional manufacturing processes;
  5. Application of metal friction stir additive manufacturing technology in the repair, remanufacturing, and fabrication of complex metal parts;
  6. Case studies on the industrial applications of metal friction stir welding/additive manufacturing technologies.

Dr. Peng Dong
Dr. Zhifeng Yan
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • friction stir welding (FSW)
  • friction stir additive manufacturing (FSAM)
  • microstructure
  • mechanical properties
  • material flow
  • process optimization
  • numerical simulation
  • tool design

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Published Papers (2 papers)

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Research

24 pages, 13221 KiB  
Article
Initial Characterization of the Layer Interface for Graphite-Free Additive Friction Stir Deposition of AA7075
by Jacob Hansen, Andrew Holladay, Luk Dean, Aaron Christiansen, Michael Merrell, Yuri Hovanski and Scott Rose
Metals 2025, 15(6), 614; https://doi.org/10.3390/met15060614 - 29 May 2025
Viewed by 111
Abstract
Additive friction stir deposition (AFSD) is a novel friction stir technology. It is one of the most prolific solid-state metal deposition processes. In recent years, the aerospace and defense industries have increased their investment in the deposition of 7xxx aluminum alloys. This has [...] Read more.
Additive friction stir deposition (AFSD) is a novel friction stir technology. It is one of the most prolific solid-state metal deposition processes. In recent years, the aerospace and defense industries have increased their investment in the deposition of 7xxx aluminum alloys. This has allowed AFSDs of 7xxx aluminum to move from a laboratory environment to being tested in an industrial setting. This work strives to help move the AFSD of AA7075 toward an effective production environment by providing an initial characterization of the graphite-free layer interface. To the authors’ knowledge, this is the first graphite-free study to utilize both knub–scroll and scroll tools in AA7075. It is also the first study to compare how flat, knub, knub–scroll, and scroll influence layer mixing in graphite-free AA7075. The condition of the layer interface is particularly important to build direction properties. As many end users of AFSD desire isotropic properties, improving build direction properties is extremely important. This work looks at how external tool geometries and layer height impact the layer interface. The objective is to not only better characterize the layer interface but also to determine if a specific external geometry and or layer height could help facilitate a stronger layer interface. It was found that depositions made by the knub tool at a 2.5 mm layer height generated the most visually consolidated layer interface at an optical and SEM level. Under EDS analysis, the knub tool only saw a 12% variation between peak and background oxygen counts. EBSD scans also revealed a more consistent grain size distribution. Full article
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16 pages, 5079 KiB  
Article
Microstructure and Properties of 6061 Aluminum Alloy by Additive Friction Stir Deposition
by Han Gao, Peng Dong and Zhiwei Wei
Metals 2025, 15(5), 539; https://doi.org/10.3390/met15050539 - 13 May 2025
Viewed by 272
Abstract
Additive friction stir deposition (AFSD) enables solid-state, layer-by-layer metal deposition, minimizing defects and elemental loss from melting. Consequently, AFSD is highly effective for manufacturing aluminum alloys. Systematic studies indicate that grain structure influences properties along different processing directions in AFSD aluminum alloys. Accordingly, [...] Read more.
Additive friction stir deposition (AFSD) enables solid-state, layer-by-layer metal deposition, minimizing defects and elemental loss from melting. Consequently, AFSD is highly effective for manufacturing aluminum alloys. Systematic studies indicate that grain structure influences properties along different processing directions in AFSD aluminum alloys. Accordingly, this study used AFSD to fabricate an aluminum alloy wall and rigorously characterized its microstructure and mechanical properties in both the XOY plane (X direction) specimen and the YOZ plane (Z direction) specimen. Results demonstrate that AFSD-fabricated 6061 aluminum alloys exhibit refined grains. Microhardness tests revealed directional variation, with the YOZ plane (Z direction) specimens showing lower hardness. Tensile tests showed that the transverse direction (X direction) specimens had slightly higher tensile strength than the deposition direction (Z direction) specimens. This study offers theoretical guidance for optimizing AFSD metal fabrication and provides data supporting the broader adoption of AFSD-fabricated 6061 aluminum alloys. Full article
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