A process–structure–property ICME framework for additive friction stir deposition repair of aluminum alloys

• ICME framework links AFSD process conditions to microstructure and yield strength. • Coupled process-microstructure modeling predict precipitation evolution during AFSD. • Distinct strengthening pathways identified for STH and MTH AFSD strategies. • Model validated using experimental demonstrations on AA7050 aluminum alloy. Additive Friction Stir Deposition (AFSD) is a novel solid-state additive manufacturing process that is particularly suitable for repair of aluminum alloys. In this study, an Integrated Computational Materials Engineering (ICME) framework is developed to establish process–structure–property (PSP) relationships for AFSD repair of aluminum alloys, with a demonstration example of through-hole repairs in AA7050-T7451. Stationary Tool Head (STH) and Moving Tool Head (MTH) approaches are examined for straight and beveled geometries with diameters of 0.25 and 0.5-inch. Thermal histories during deposition are obtained using in-situ thermocouple measurements supplemented by COMSOL simulations and serve as inputs for precipitation simulations using the TC-Prisma module in Thermo-Calc. The predicted microstructural evolution is coupled with a physics-based yield strength model that shows good agreement with experimentally estimated yield strength derived from hardness measurements calibrated using AFSD-specific regression model. Results show that strength evolution during AFSD is primarily governed by precipitate dissolution and coarsening under STH conditions, while MTH processing results in lower thermal exposure, enabling alternative strengthening pathways. The ICME framework presented provides a predictive foundation for AFSD process optimization supporting its broader adoption as an advanced solid-state manufacturing and repair technology for aluminum alloys