| Summary: | Additive manufacturing is playing a crucial role in Industry 4.0, rapidly shifting its application from research and development in prototyping to the fabrication of industrial parts. Laser-based additive manufacturing (LAM) techniques have been adopted widely and become the most researched area in metal additive manufacturing. However, porosity and residual stresses developed during the LAM process create a bottleneck between industrial demands and process capabilities. Additive friction stir deposition (AFSD) is a process that has the ability to overcome these limitations as well as providing additively-manufactured structures that possess superior microstructure and mechanical properties. The enhanced mechanical and microstructural properties of the deposited structure, its relative ease of use, flexibility in the feed material, and scalability confers AFSD a huge potential in the metal additive manufacturing process. This chapter focuses on the key aspects of AFSD with an emphasis on the investigations of microstructural and mechanical properties of the resulting product. This chapter aims to provide researchers and industrial professionals with an understanding of the fundamental aspects of AFSD, its experimental setup, its process-property relationship and the current process limitations related to reinforcement loading, in-pane resolution and tool wear. The advantages and limitations of AFSD compared to other additive manufacturing techniques and scope for improvements are also discussed. © 2024 selection and editorial matter, Amlan Kar and Zafar Alam, individual chapters.
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