Abstract: Solid-state additive manufacturing methods for compounding conductive plastic compositions, fabrication of conductive plastic parts and conductive coatings, and plastic recycling are disclosed. Electrically conductive or thermally conductive plastic compositions are compounded and subsequently printed with the solid-state additive manufacturing system. The solid-state fabricated compositions, parts and coatings can also be manufactured to be both thermally and electrically conductive. Solid-state plastic waste recycling methods are also disclosed where various plastic waste materials and shapes are solid-state processed. The plastic waste can be mixed with virgin plastic material or mixed with other types of materials such as metals, ceramics or their combination. The waste plastic feedstock is reinforced with different types of reinforcing particles or fibers, or various additives are added for improving properties of the final deposits.

Abstract: A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations.

Abstract: A solid-state additive manufacturing additive manufacturing system applicable to building up 3D structures, coating and functionalizing surfaces, joining structures, adding customized features to objects, compounding proprietary compositions and repairing various structures is disclosed. The solid-state additive manufacturing system enables deposition of different fillers, viz. metals, metal alloys, MMCs, polymers, plastics, composites, hybrids and gradient compositions, as well as controls the resulting deposit structures, e.g. specific nano-/micro-, gradient- and porous-material structures. The system accommodates various feeding-, spindle- and tool-designs for depositing different forms of filler materials, viz. rods, wires, granules, powders, powder-filled-tubes, scrap pieces or their combination, and a working platform with multiple access points.

Abstract: A method for joining materials using additive friction stir techniques is provided. The method joins a material to a substrate, especially where the material to be joined and the substrate are dissimilar metals. One such method comprises (a) providing a substrate with one or more grooves; (b) rotating and translating an additive friction-stir tool relative to the substrate; (c) feeding a filler material through the additive friction-stir tool; and (d) depositing the filler material into the one or more grooves of the substrate. Translation and rotation of the tool causes heating and plastic deformation of the filler material, which flows into the grooves of the substrate resulting in an interlocking bond between the substrate and filler material. In embodiments, the depositing of the filler material causes deformation of the grooves in the substrate and an interlocking configuration between the grooves of the substrate and the filler material results.

Abstract: An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion.