Enabling Aluminum 7075 Forgings via Additive Friction Stir Deposition for Defense Needs

The demand for high-strength 7XXX-series aluminum continues to place pressure on conventional forging infrastructure within the defense and aerospace sectors. Conventional forging capacity is limited; lead times are long, and the ability to produce large aluminum 7075 components on demand remains a challenge. Additive Friction Stir Deposition (AFSD) addresses this gap through a novel forging process deployable in an additive configuration, yielding 7075 aluminum with wrought microstructure and performance unachievable by melt-based additive processes.
This presentation will review the development and qualification of 7075 forgings produced via AFSD. Earlier trials of the process relied on lubricated feedstock to support deposition; however, through rigorous internal R&D and system-level redesign efforts, our team has eliminated graphite dependency and achieved stable, repeatable processing of aerospace-grade 7075. This advancement required parallel progress in both material understanding and machine capability, resulting in next-generation systems purpose-built to deliver the process control, downforce, and thermal management necessary for 7XXX alloys.
Equally significant has been the maturation of the broader AFSD community. The first process specification for AFSD has been drafted under AWS, and a MIL-SPEC for AFSD 7075 material is now in development, together establishing the qualification framework for defense adoption. These efforts contribute to a growing framework for qualification and adoption within defense and aerospace applications, emphasizing the transition from a promising process to a production-ready solution.
Attendees will gain insight into how AFSD enables the delivery of 7075 aluminum forgings, including process evolution, material performance, and emerging standards. The presentation will highlight how AFSD bridges the gap between additive manufacturing and forging, offering a pathway toward distributed, resilient production of aerospace-grade components.