Friction stir processing of direct metal deposited copper-nickel 70/30

Research highlights: → FSP of laser-deposited copper-nickel 70/30 leads to extensive grain refinement and reduction in porosity. → UTS of friction stir processed copper-nickel 70/30 is similar to laser-deposited material but the ductility of the former is much less than the latter. → Corrosion resistance of friction stir processed copper-nickel 70/30 is higher than laser-deposited material. - Abstract: Friction stir processing (FSP) was carried out on a multi-layered copper-nickel 70/30, deposited on a copper-nickel 70/30 substrate via laser-assisted direct metal deposition (DMD). Microstructural changes associated with single and overlapping FSP passes were analyzed using electron microscopy. Mechanical property and corrosion behavior were also evaluated before and after FSP. It was observed that FSP reduces porosity, refines grains, increases hardness, reduces ductility and increases corrosion rate in comparison to DMD copper-nickel 70/30.