Wire arc additive manufacturing deposition with solid-state recycled wire processed via friction stir extrusion

Sustainability is increasingly important in modern engineering, influencing both product design and manufacturing processes. Friction stir extrusion has emerged as a promising method for recycling aluminum chips in the solid state, offering energy savings compared to traditional remelting recycling processes. This study investigates the use of solid-state recycled wires, processed through friction stir extrusion, as filler materials in wire arc additive manufacturing (WAAM) based on gas metal arc welding (GTAW) process. The research studied the feasibility of the application, addressing key processes and metallurgical challenges and aspects to be improved. The results show that using the friction stir extruded wires is feasible, but there are still challenges to overcome, such as impurities, geometric variations, and porosity. With further optimization in cleaning treatments and welding parameters, recycled friction stir extruded materials hold promise for sustainable manufacturing.