An apparatus and method for a continuous supply of feedstock for a friction stir additive manufacturing method has a rod supply system that transports feedstock segments to a shuttle. The rod supply system has actuators that are coupled to allow movement of the delivery point of the feedstock. The shuttle indexes the feedstock to be on axis with the spindle and rotates it to match the speed and orientation of the spindle before it makes contact with other feedstock currently being deposited. An upper thrust mechanism moves the feedstock from the shuttle to a one-way collet and applies deposition pressure through the collet while the collet raises. Once raised, the collet then applies deposition pressure to the feedstock and the upper thrust mechanism retracts so the shuttle can index again and present additional feedstock. The process can repeat to continuously supply feedstock until the workpiece is complete.

A solid state additive method includes: disposing a round consumable rod in a hollow stirring tool; based on a coating layer height, setting a gap between a bottom surface of the hollow stirring tool and a base surface; driving the hollow stirring tool to rotate at a first rotation speed; driving the consumable rod to rotate at a second rotation speed, where the second rotation speed and the first rotation speed are different in angular speed to form a differential, such that the consumable rod rubs against an inner wall of the hollow stirring tool to generate thermal deformation so as to obtain a plastic deformation flow in the hollow stirring tool; pressing the consumable rod downward to enable the plastic deformation flow to be in friction contact with the base surface; translating the hollow stirring tool and stirring the base surface.

A hollow metal member manufacturing method for manufacturing a hollow metal member, which is a metal member having an internal space, by using a rotation tool, includes: a step of preparing a recessed metal member in which a recessed portion corresponding to a desired internal space shape is formed from a surface to an inside of the metal member; and a step of moving the rotation tool along an opening of the recessed portion while pressing the rotation tool against an opening surface, which is a surface of the recessed metal member on which the recessed portion is formed, and closing the recessed portion with a softened material of the opening surface.

A repair system for a part for a gas turbine engine includes a deposition system that implements a friction stir additive manufacturing (FSAM) process. An inspection system coupled to the repair system identifies a region of interest having damage on the part. A process for deposition of metallic deposition material onto the region of interest performed using the deposition system. A rod of the metallic deposition material is moved using pressure exerted within the deposition system into a deposition zone of the region of interest. The region of interest is pre-heated prior to the pressure being exerted. Frictional heat is generated when the rod contacts the deposition zone. Parameters to control the components within the deposition system are determined using a function and a depth of the layers of the metallic deposition material determined for enabling the repair process.

A friction stir additive manufacturing system is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, and a housing configured to receive at least a portion of the spindle, the housing configured to remain stationary relative to the spindle. The housing includes a wire inlet extending between an exterior surface of the housing and an interior surface of the housing, and a track extending from the wire inlet and partially around a circumference of an interior surface of the housing. The system also includes a feeding system configured to receive a wire from a roller and feed the wire through the wire inlet and into the track of the housing.

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.