Abstract
This article presents optical images, measurements of heat affected zone depths, and peak Vickers hardness values from the heat affected zone regions of a 1080 steel plate substrate with a machined groove "flaw" repaired using additive friction stir deposition of Aermet 100. The deposition of Aermet 100 was performed using a L3 Meld machine with 9.525 mm (0.375 inch) square bar profile Aermet 100 feedstock rods fed through a hollow, 10.16 mm (0.4 inch) diameter, rotating tool onto a 1.02 mm thick 1080 steel plate with a machined groove "flaw" along the plate's length and bisecting the plate's width. The depth of the machined groove "flaw" ranged from 4.7625, 6.35, and 9.525 mm. The data is categorized into four groups: multi-layer builds deposited at room temperature with and without a cooling plate, 2-layer builds deposited at room temperature without a cooling plate, single-layer builds deposited at room temperature without a cooling plate, and a design of experiments for single-layer builds that varied the spindle rotation speed (RPM), travel speed (mm/min), material feed rate (mm/min), and pre-heat temperature (°C) of the deposition. The data shows the parameter conditions that achieved flaw-free consolidated repairs and the associated depth and peak Vickers hardness of the heat affected zone. Optical images of cross-sectioned deposition regions were obtained using an optical microscope with Leco Olympus DP27 macro camera, and Vickers hardness line traces were measured along the depth of the deposited and heat affected zone extending into the substrate on cross-sectioned samples using a Leco LM 247AT microhardness tester. The depth of the heat affected zone is reported as the measured average of five individual data points. Peak values for Vickers hardness for the heat affected zone decreased for pre-heated conditions at 329°C compared to builds conducted at room temperature of 21°C. This dataset provides visual characterization and associated hardness measurements of as-deposited repairs of dissimilar steel alloys. This article can be used to inform parameter selection for additive friction stir deposition of dissimilar steel materials for repair and solid-state additive manufacturing applications.