MELD®: An Additive Forging Process for Titanium Alloys

Additive Friction Stir Deposition (AFSD), also known as the MELD process, is a solid-state alternative to traditional forging for titanium alloys. Operating below the melting point, AFSD produces fully dense parts with properties equivalent to forgings. Titanium alloys such as Ti-6Al-4V and Ti-10-2-3 are particularly well-suited for this process, benefiting from high deposition rates and low residual stresses. With simple and cost-effective tooling, AFSD enables near-net shape production, reducing the need for extensive post-processing.
This presentation reviews the application of AFSD as an additive forging method for titanium alloys, focusing on its ability to achieve isotropic mechanical properties that meet or exceed standards for forged materials. We’ll discuss performance data, including tensile and fatigue results, and how AFSD can serve as a practical and scalable alternative to conventional forging in demanding aerospace and industrial applications.