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A solid-state and continuous groove repair technology was proposed for aluminium alloy based on friction rolling additive manufacturing (FRAM). The feasibility of FRAM was explored by repairing three types of prefabricated groove damages in aluminium alloy plates. A well-repaired joint for trapezoidal groove was obtained when the press-in depth of the tool head was 2 mm. The press-in depth was the key factor to complete filling of the groove damage. Effective grain refinement of the repair centre and the significant refinement area are observed, which leads to the hardness of these two areas reaching 99% and 102% of the substrate, respectively. The material migration behaviour of the filling material during the process was clarified.

Continuous repair of groove damages using solid-state friction rolling additive manufacturing method