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Investigation of Additive Friction Stir Deposition of Inconel 718: Mechanical Performance and Microstructural Evolution.

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Title: Investigation of Additive Friction Stir Deposition of Inconel 718: Mechanical Performance and Microstructural Evolution.
Authors: Zavari, Saeid1 (AUTHOR), Emanet, Selami1,2 (AUTHOR), Ding, Huan1 (AUTHOR), Ensafi, Mahnaz1,2 (AUTHOR), Bagheri, Ehsan1 (AUTHOR), Schmidt, Carl2 (AUTHOR), Dulik, Jeff2 (AUTHOR), Guo, Shengmin1 (AUTHOR)
Source: Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2482. 19p.
Subjects: Inconel, Microstructure, Friction stir processing, Tensile tests, Grain refinement, Anisotropy, Recrystallization (Metallurgy), Mechanical efficiency
Abstract: Additive friction stir deposition (AFSD) is a solid-state additive manufacturing process that enables the fabrication of fully dense metallic components without common fusion-related defects. Inconel 718, widely used in aerospace and energy sectors, requires high structural reliability; therefore, evaluating its response to AFSD is essential for advanced applications. This study investigates the effects of AFSD on IN718 by comparing the mechanical properties and microstructure of the as-deposited material with the feedstock condition. Tensile testing showed that the ultimate tensile strength (UTS) increased by 5% along the traverse direction, whereas elongation was reduced compared to the feedstock. In contrast, build-direction tensile specimens exhibited lower UTS and substantially reduced elongation, revealing mechanical anisotropy. Microhardness increased by 20%, consistent with substantial grain refinement from 11 µm to 3 µm due to dynamic recrystallization during deposition. X-ray diffraction (XRD) revealed no clearly detectable secondary phase formation after AFSD within the resolution limits of conventional XRD, suggesting that the increased hardness and traverse-direction strength can be partly explained by grain refinement. Elemental mapping detected oxygen-enriched Al/Ti regions at interlayer boundaries, which may contribute to the reduced build-direction ductility. Overall, AFSD refined the microstructure, enhanced hardness, and improved traverse-direction strength, while build-direction tensile testing revealed anisotropic mechanical behavior. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Investigation of Additive Friction Stir Deposition of Inconel 718: Mechanical Performance and Microstructural Evolution.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2482. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Inconel%22">Inconel</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Friction+stir+processing%22">Friction stir processing</searchLink><br /><searchLink fieldCode="DE" term="%22Tensile+tests%22">Tensile tests</searchLink><br /><searchLink fieldCode="DE" term="%22Grain+refinement%22">Grain refinement</searchLink><br /><searchLink fieldCode="DE" term="%22Anisotropy%22">Anisotropy</searchLink><br /><searchLink fieldCode="DE" term="%22Recrystallization+%28Metallurgy%29%22">Recrystallization (Metallurgy)</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+efficiency%22">Mechanical efficiency</searchLink>
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  Data: Additive friction stir deposition (AFSD) is a solid-state additive manufacturing process that enables the fabrication of fully dense metallic components without common fusion-related defects. Inconel 718, widely used in aerospace and energy sectors, requires high structural reliability; therefore, evaluating its response to AFSD is essential for advanced applications. This study investigates the effects of AFSD on IN718 by comparing the mechanical properties and microstructure of the as-deposited material with the feedstock condition. Tensile testing showed that the ultimate tensile strength (UTS) increased by 5% along the traverse direction, whereas elongation was reduced compared to the feedstock. In contrast, build-direction tensile specimens exhibited lower UTS and substantially reduced elongation, revealing mechanical anisotropy. Microhardness increased by 20%, consistent with substantial grain refinement from 11 µm to 3 µm due to dynamic recrystallization during deposition. X-ray diffraction (XRD) revealed no clearly detectable secondary phase formation after AFSD within the resolution limits of conventional XRD, suggesting that the increased hardness and traverse-direction strength can be partly explained by grain refinement. Elemental mapping detected oxygen-enriched Al/Ti regions at interlayer boundaries, which may contribute to the reduced build-direction ductility. Overall, AFSD refined the microstructure, enhanced hardness, and improved traverse-direction strength, while build-direction tensile testing revealed anisotropic mechanical behavior. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
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  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19122482
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        Text: English
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        StartPage: 2482
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      – SubjectFull: Inconel
        Type: general
      – SubjectFull: Microstructure
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      – SubjectFull: Friction stir processing
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      – SubjectFull: Tensile tests
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      – SubjectFull: Grain refinement
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      – SubjectFull: Anisotropy
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      – SubjectFull: Recrystallization (Metallurgy)
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      – SubjectFull: Mechanical efficiency
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      – TitleFull: Investigation of Additive Friction Stir Deposition of Inconel 718: Mechanical Performance and Microstructural Evolution.
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              Text: Jun2026
              Type: published
              Y: 2026
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