Welding and wire arc additive manufacturing using FSE solid-state recycled wires: Challenges and future perspectives

Friction stir extrusion (FSE) is an interesting process for recycling aluminium chips. It significantly reduces waste and energy consumption by recycling materials without remelting. The possibility of producing continuous wires by FSE allows the possibility of using it as an input material in welding processes, which can significantly improve the sustainability of aluminium manufacturing. This study explores the use of FSE-recycled wires in welding and their feasibility for wire arc additive manufacturing, investigating the potential, challenges, and improvement methods for developing the process. The results show that the FSE-recycled wires can be effectively used for welding deposition. However, improving chip cleaning treatments is crucial for reducing hydrogen and oxides to further improve this application. With some improvements, potential applications and fitness for purpose can be envisioned for the process, offering an interesting circular approach in aluminum manufacturing.