Recent Research Progress in Solid-State Friction-Based Additive Manufacturing Technology and Its Current Applications

doi:10.11900/0412.1961.2025.00233

Acta Metall Sin

2026, Vol. 62

Issue (1): 100-116 DOI: 10.11900/0412.1961.2025.00233

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Recent Research Progress in Solid-State Friction-Based Additive Manufacturing Technology and Its Current Applications

LIU Haibin¹, ZHANG Yingxing¹, XIE Ruishan¹^,², CHEN Shujun¹(

)

1 College of Mechanical and Energy Engineering, Beijing University of Technology, Beijing 100124, China
2 Chongqing Research Institute of Beijing University of Technology, Chongqing 401121, China

Cite this article:

LIU Haibin, ZHANG Yingxing, XIE Ruishan, CHEN Shujun. Recent Research Progress in Solid-State Friction-Based Additive Manufacturing Technology and Its Current Applications. Acta Metall Sin, 2026, 62(1): 100-116.

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Abstract

Metal additive manufacturing is highly valued in the industrial field due to its ability to rapidly produce complex lightweight structures. However, molten metal additive manufacturing technologies are prone to defects such as compositional segregation, internal holes, and thermal cracks, which has driven researchers to develop alternative approaches. In recent years, solid-state friction-based additive manufacturing, derived from the principle of friction stir welding, has attracted considerable attention. This technology combines friction stir welding with the additive manufacturing concept and offers several advantages, including the avoidance of material melting during processing, high deposition rates, and the elimination of the need for protective gas. These advantages suggest broad application prospects for this technology in the field of metal structural parts manufacturing. This study systematically reviews the progress of solid-state friction-based additive manufacturing technology, domestically and internationally, outlining its technical classification, process-microstructure-property relationships, technological advantages, equipment development, sample fabrication, and solid-state repair applications. Finally, the study summarizes the current challenges faced by the process and explores its future development potential, aiming to promote the industrialization of solid-state friction-based additive manufacturing technology and to serve as a reference for further research and applications.

Key words: solid-state friction-based additive manufacturing technology complex component application status solid-state repair

Received: 14 August 2025

ZTFLH:

TG439.8

Fund: National Defense Basic Research Projects of China(JCKY2022405C002);National Natural Science Foundation of China(52275299);National Natural Science Foundation of China(52105313);Aeronautical Science Foundation of China(20240011075001);Natural Science Foundation of Chongqing(CSTB2023NSCQ-MSX0701)

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	LIU Haibin
	ZHANG Yingxing
	XIE Ruishan
	CHEN Shujun

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00233 OR https://www.ams.org.cn/EN/Y2026/V62/I1/100

Fig.1 Metal additive manufacturing technology

Fig.2 Steps in the fabrication of friction stir additive manufacturing (FSAM)^[23]

Fig.3 Schematic of the machining process of friction surface deposition additive manufacturing (FSDAM) (ND—normal direction, TD—transverse direction, BD—building direction)

Fig.4 Schematic of additive friction stir deposition (AFSD) process

Fig.5 Additive friction extrusion deposition (AFED) principle and application

Fig.6 Overview of the friction screw extrusion additive manufacturing (FSEAM) process (a-e)^[48] (Ω—tool rotation rate, t_l—layer thickness, V_f—volumetric supply rate, v_t—translational speed, W—layer width)

Fig.7 Schematic of the friction rolling additive manufacturing (FRAM) process

Fig.8 Schematics of grain evolution during the AFSD process (a)^[83] and grain distribution of the feedstock and the deposited material on the XZ, YZ, and XY planes during the FRAM process (b)^[84] (d_AG—average grain size)

Fig.9 Hardness results on yz-plane of three samples deposited via different processes^[62]
(a) FRAM (b) preheating FRAM (P-FRAM)
(c) preheating and water-cooling-assisted FRAM (PC-FRAM)

Fig.10 Stress-strain curves (a) and tensile test results (b) of the 7075 and FRAM 7075-TiC alloys, and comparison of tensile performance for additively manufactured Al-Zn-Mg-Cu alloys produced by different techniques (c)^[1] (UTS—ultimate tensile strength, YS—yield strength, EL—elongation)

Table 1 Applicable materials for solid-state friction-based additive manufacturing technology

Table 2 Technical characteristics of different solid-state friction additive manufacturing processes

Fig.11 Solid-state friction additive manufacturing equipments
(a) multi-functional solid-state composite additive equipment of Aerospace Engineering Equipment (Suzhou) Co. Ltd.^[6]
(b) solid-state composite additive equipment of MELD Corporation (USA)^[100]
(c) FSAM equipment developed by the U.S. Army^[6]
(d) FSAM850 stirring friction additive manufacturing equipment^[10] (CNC—computer numerical control)
(e) vertical machining center FRAM1165 equipment
(f) FRAM2213 gantry machining equipment
(g) solid phase friction extrusion AFSD equipment^[6]
(h) the largest AFSD equipment in the world^[6]

Fig.12 Schematics of the main structural components of the Orion manned spacecraft (a), experimental apparatus for FSAM process production (b), airborne floor components (c), and alloy reinforcement rings on pressure vessels (d)^[5] (FSW—friction stir welding)

Fig.13 Prototypes fabricated by MELD Corporation (USA) using AFSD^[100]

Fig.14 Several typical components fabricated using FRAM technology
(a) single-walled member (b) aluminum alloy cylinder^[54]
(c) U-shaped sample (d) criss-cross sample
(e) C-shaped sample (f) large circular member
(g) aluminum/steel heterogeneous structure^[57] (h) sample of high-bar plate siding^[93]

Fig.15 Reducing structure, hemispherical shell, and flange ring structure (a) and the screw-fed powder-based AFSD experiment and the resulting alloy specimens (b)^[106]

Fig.16 Applications in the field of restoration, including schematic of restoration of multiple defect forms^[58] (a), structural repair of holes^[100] (b), and thin-walled plate restoration^[93] (c) (RD—rolling direction)

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[1]	LI Huizhao, WANG Caimei, ZHANG Hua, ZHANG Jianjun, HE Peng, SHAO Minghao, ZHU Xiaoteng, FU Yiqin. Research Progress of Friction Stir Additive Manufacturing Technology[J]. 金属学报, 2023, 59(1): 106-124.

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