Effects of shear bond on quality of Friction stir additive manufactured copper

This study investigates the influence of the shear bond in friction stir additive manufacturing (FSAM) on the quality of printed copper sample. The shear bond is a mixture of thermo-mechanical affected zone (TMAZ) and re-heat affected zone (RAZ), formed around the ultra-fine grain region during FSAM. The shear bond is plays a crucial role in modifying the microstructure and mechanical properties of the printed layers. It is demonstrated that the presence of the shear layer enhances material strength, ductility, and fracture resistance, leading to improved overall quality of the printed samples. The microstructure size of the shear bond is 67.5% smaller than that of copper. This distinctive layer contributes to a notable 20% enhancement in the FSAM sample's performance.