Current work explored solid-state additive manufacturing of AZ31B-Mg alloy using additive friction stir deposition. Samples with relative densities ≥ 99.4% were additively produced. Spatial and temporal evolution of temperature during additive friction stir deposition was predicted using multi-layer computational process model. Microstructural evolution in the additively fabricated samples was examined using electron back scatter diffraction and high-resolution transmission electron microscopy. Mechanical properties of the additive samples were evaluated by non-destructive effective bulk modulus elastography and destructive uni-axial tensile testing. Additively produced samples experienced evolution of predominantly basal texture on the top surface and a marginal increase in the grain size compared to feed stock. Transmission electron microscopy shed light on fine scale precipitation of Mg[Formula: see text]Al[Formula: see text] within feed stock and additive samples. The fraction of Mg[Formula: see text]Al[Formula: see text] reduced in the additively produced samples compared to feed stock. The bulk dynamic modulus of the additive samples was slightly lower than the feed stock. There was a [Formula: see text] 30 MPa reduction in 0.2% proof stress and a 10-30 MPa reduction in ultimate tensile strength for the additively produced samples compared to feed stock. The elongation of the additive samples was 4-10% lower than feed stock. Such a property response for additive friction stir deposited AZ31B-Mg alloy was realized through distinct thermokinetics driven multi-scale microstructure evolution.
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