Microstructure and mechanical properties of 2195 Al-Li alloy via friction stir additive manufacturing with different stirring paths

Friction stir additive manufacturing (FSAM) is increasingly becoming a feasible method for aluminum alloy structure due to the unique forming characteristics. In this study, two different stirring paths were explored for 2195 Al-Li alloy and the microstructure evolution and mechanical properties were ‌investigated. An ultrafine grained microstructure was formed in the FSAMed zone with an average grain size ranging from 1 to 5μm. The microstructure in the FSAMed zone at the bottom exhibited a consistent direction trend and a significant increase in dislocation density. Different stirring paths had minimal impact on the phase distribution. Frictional heating led to the re-dissolution and re-precipitation of precipitates, resulting in T1, θ', and δ'/β' were distributed within the grains. The samples of intersecting stirring path showed similar mechanical properties in different directions, while the UTS of LD was 52.56 MPa higher than TD of the reciprocating path samples. The microhardness range for the intersecting stirring path ranged from 87.0 HV_0.2 to 126.6 HV_0.2, while the reciprocating stirring path exhibited a microhardness range of 83.8 HV_0.2 to 132.4 HV_0.2. In summary, this study provides valuable insights into designing processing paths for FSAM of 2195 Al-Li alloy.