AccScience Publishing / MSAM / Volume 4 / Issue 4 / DOI: 10.36922/MSAM025280060
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ORIGINAL RESEARCH ARTICLE

Influence of tool head geometry on in situ monitoring of temperature, force, and torque during additive friction deposition of aluminum alloy 2219

Qian Qiao1 ,  Xiumei Gong2 ,  Dawei Guo1,3* ,  Hongchang Qian4 ,  Zhong Li4 ,  Dawei Zhang4 ,  Chi Kwok5 ,  Lap Mou Tam1,3,5*
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1 IDQ Science and Technology (Hengqin Guangdong) Co., Ltd., Zhuhai, Guangdong, China
2 Aerospace Engineering Equipment (Suzhou) Co., Ltd., Suzhou, Jiangsu, China
3 Institute for the Development and Quality, Macao, China
4 National Materials Corrosion and Protection Data Center, Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing, China
5 Department of Electromechanical Engineering, Faculty of Science and Technology, University of Macau, Macao, China
MSAM 2025, 4(4), 025280060 https://doi.org/10.36922/MSAM025280060
Received: 9 July 2025 | Accepted: 5 August 2025 | Published online: 4 September 2025
© 2025 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

Additive friction stir deposition (AFSD) has emerged as an effective method for producing uniform grain structures with enhanced mechanical properties. However, in the field of AFSD, there remains a lack of a systematic and clear description regarding the specific impact of tool head geometry on the structure and properties of fabricated deposits. This study investigates the effect of tool head geometry on aluminum alloy 2219 (AA2219) fabricated by AFSD. In situ monitoring data showed that deposition using a tool with two protrusions promoted sufficient material flow and increased plastic deformation. This resulted in a refined microstructure without abnormal grain growth. Enhanced mechanical properties were observed, including a microhardness of 92.2 HV0.5, yield strength of 315.8 MPa, ultimate tensile strength of 371.6 MPa, and an elongation of 6.8%, which were attributed to grain refinement and precipitation strengthening. Furthermore, corrosion resistance improved compared to deposits fabricated without protrusions, owing to grain refinement and a reduction of the aluminum–copper phase. The findings advance the understanding of the solid-state additive manufacturing process and offer new insights into achieving high-quality AA2219 deposits.

Graphical abstract
Keywords
Additive friction stir deposition
In situ monitoring
Tool head geometry
Mechanical properties
Corrosion resistance
Funding
This study was funded by the Science and Technology Development Fund (FDCT) of Macau SAR (0110/2023/ AMJ), the National Key Research and Development Program of China (2023YFE0205300), and the Guangdong Basic and Applied Basic Research Foundation (2021B1515130009).
Conflict of interest
The authors declare that they have no known competing financial interests or personal relationships that could have influenced the work reported in this paper.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing
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