Methods, systems, and apparatuses for component manufacturing are provided. A component may be manufactured via an extrusion of loose substrate material into a unitary tubing. Features may be added to the tubing via friction stir additive manufacturing to manufacture a component. In this manner, a component may be manufactured from titanium alloys while processing challenges such as iron segregation or material loss through machining are ameliorated. Such a component may replace steel or other high strength components and further exhibits corrosion resistance.

An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion.

This invention discloses a 3D printing apparatus and method utilizing friction stir welding (FSW). The apparatus includes a material feeding mechanism, a control mechanism, a friction stir welding (FSW) mechanism, and a friction stir welding (FSW) rotation drive mechanism. The control mechanism controls the material feeding mechanism, the FSW mechanism and the FSW rotation drive mechanism. In addition to the control mechanism, the FSW mechanism also connects to the FSW rotation drive mechanism. The method comprises the steps of: 1, start the control mechanism; step 2, the control mechanism controls the material feeding mechanism to feed filling material; step 3, print 3D product with FSW mechanism. The invention achieves additive manufacturing and 3D printing with a new friction stir welding technology. The invented method has many advantages such as can handle a wide range of raw materials, has high printing speed, has high efficiency, has low energy consumption, requires low cost, is broadly applicable in different situations, is environmentally friendly, and is easy to automate. The products manufactured following this invention is formed through semi-solid forming technology. They will have good mechanical properties and low price.

Additive manufacturing systems and methods are disclosed. A housing includes a passageway having first and second open ends. A material is fed through the passageway and exits its second open end. A friction stir weld (FSW) bobbin pin tool is mounted in the housing with a radial edge of the pin tool's annular volume disposed adjacent to the second open end of the passageway. The annular volume is adapted to receive a substrate. The FSW bobbin pin tool is operable to be rotated so that the substrate and the material exiting the second open end of the passageway are plasticized in the annular volume for deposition onto the substrate.

Additive friction stir methods for repairing substrates, coating substrates, fabricating/adding/attaching ribs, joining substrates, stiffening and enhancing structures, surface modification, enhancing surface properties, welding, coating, and extrusion are described. An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a substrate or to repair a defect in a substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the substrate. Further described is a system for fabricating a rib joined to a substrate through extrusion.

A method of manufacturing an article is described. At S102, the method comprises obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy. At S104, the method comprises providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy. At S106, the method comprises depositing a third layer on the second layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy.

A method of manufacturing an article is described. At S102, the method comprises obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy. At S104, the method comprises providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy. At S106, the method comprises depositing a third layer on the second layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy.

An manufacturing installation for manufacturing a manufactured object by additive friction stir deposition includes a manufacturing system configured to manufacture a manufactured object by additive friction stir deposition from a manufacturing material, and a feed system configured to feed the manufacturing system with manufacturing material. The feed system includes a spool of a manufacturing material wire wound about a spool axis; an unwinding device configured to unwind the wire, to drive the spool in rotation about a principal axis of rotation and to drive the wire in rotation about its neutral fiber; and a device for guiding the unwound wire to the manufacturing system.

An additive manufacturing system for additive manufacturing a feedstock material upon a substrate comprising a feedstock supplying system configured to supply the feedstock material; and an extrusion die system having a rotating drive system configured to rotate an extrusion die member relative to and in physical contact with the stationary feedstock material to generate friction sufficient to locally heat the feedstock material.

A friction application device includes an application element which defines a rotational axis and which is movable by a moving device on a surface of a workpiece and in a relative movement with respect to the surface of the workpiece. At least one supporting tool is non-coaxial with the rotational axis and has an arcuate outer periphery in direct contact with the application element.