@misc{soujon_fundamental_study_2022, author={Soujon, M., Kallien, Z., Roos, A., Zeller-Plumhoff, B., Klusemann, B.}, title={Fundamental study of multi-track friction surfacing deposits for dissimilar aluminum alloys with application to additive manufacturing}, year={2022}, howpublished = {journal article}, doi = {https://doi.org/10.1016/j.matdes.2022.110786}, abstract = {Friction surfacing is an emerging solid-state coating technology based on frictional heat induced plastic deformation at the tip of a consumable metallic stud that allows to deposit layers with a fine-grained recrystallized microstructure at temperatures below the melting point. The generation of sound, defect-free metallurgical joints between multiple adjacent overlapping friction surfacing deposits, also referred to as multi-track friction surfacing, from dissimilar aluminum alloys is the focus of this experimental work. An extensive volumetric defect analysis is carried out for various overlap configurations, including post-processing strategies in order to assess the inter-track bonding integrity using microscopic characterization techniques and micro-computed tomography. The effect of layer arrangement and overlap distance on the volumetric defect formation in both inter-track and layer-to-substrate interface is quantified and discussed. Post-processing via hybrid friction diffusion bonding process demonstrates a significant reduction in defect volume ratio, proving higher material efficiency. The gained knowledge was used to successfully build a multi-track multi-layer friction surfacing stack, demonstrating the suitability of this process for large-scale additive manufacturing components. The subsequent mechanical analysis reveals excellent homogeneous isotropic tensile properties of the additive structure in the range of the base material tensile strength.}, note = {Online available at: \url{https://doi.org/10.1016/j.matdes.2022.110786} (DOI). Soujon, M.; Kallien, Z.; Roos, A.; Zeller-Plumhoff, B.; Klusemann, B.: Fundamental study of multi-track friction surfacing deposits for dissimilar aluminum alloys with application to additive manufacturing. Materials & Design. 2022. vol. 219, 110786. DOI: 10.1016/j.matdes.2022.110786}}