I want to use basic principles of Friction Stir Processing to do Additive Manufacturing of Aluminium. For this purpose, I'm trying to extrude Aluminium powder through the hollow shoulder of a simple FSP tool. But the powder gets solidified and blocks the mouth of the hole of this tool at the interface of tool and workpiece. What could be some of the mechanisms to force the powder to continuously extrude through the tool .
Yongxian Huang, Tianhao Wang, Weiqiang Guo, Long Wan, Shixiong Lv,Microstructure and surface mechanical property of AZ31 Mg/SiCp surface composite fabricated by Direct Friction Stir Processing, Materials and Design 59 (2014) 274–278.
Please read the experimental procedure in the above article. This group of authors used a hollow tool and fed the SiC particle to create a thin surface composite layer. They used tool tilting and adjusted the gap between trailing and leading edge with respect to plunging depth to avoid blockage of ceramic powders from the hole. There is a cross sectional micrograph in the paper. But no photo of the entire track is kept. It is a challenging task to create a single layer and subsequently add multiple layers to build up. Since you choose aluminum powder, it will easily block the exit hole once plasticized. You need to redesign the tooling and perhaps incorporate additional mechanism in the machine head to achieve this.
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