University of Twente Student Theses


Influence of print speed on the microstructure and mechanical properties of AA6060 FSEAM builds

Strik, D.H. (2023) Influence of print speed on the microstructure and mechanical properties of AA6060 FSEAM builds.

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Embargo date:30 March 2025
Abstract:A newly developed solid-state additive manufacturing process, called Friction Screw Extrusion Additive Manufacturing (FSEAM), employs a rotating screw in a stationary housing to deposit aluminium feedstock at low temperatures. This work focused on the effect of printing speed during the process, varying in print speeds of 100, 150, 200, and 250 mm/min. The builds revealed no macro-scale defects, but SEM microscopy showed micro-scale defects. Furthermore, EBSD revealed substantial grain refinement for all samples and the average print head temperature increased with printing speed. The hardness decreased by about 50% compared to the feedstock material. Also, the tensile tests showed a decrease in yield and tensile strength but an increase in elongation at break. Tensile strength tended to increase with print speed. The mechanical properties between samples extracted in the build and deposition directions differed significantly, where micro-scale defects only impacted the former. The stress-strain curves of the builds with an average build temperature above 400°C (150 – 250 mm/min) revealed serrated stress-strain behaviour. This behaviour was ascribed to the dissolution of strengthening precipitates within the print head during deposition. Lastly, a 2D thermal model of the build confirmed the impact of deposition speed on heat generation and temperature development.
Item Type:Essay (Master)
Faculty:ET: Engineering Technology
Subject:51 materials science, 52 mechanical engineering
Programme:Mechanical Engineering MSc (60439)
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