Resistance seam welding additive manufacturing (RSAM) is a new solid-state additive manufacturing technique that utilizes pulsed current and pressure to welding powders layer by layer. In this study, Al1060 powder was employed as the raw material to prepare R0 and R10 samples through RSAM technology and subsequent repeated welding processes, respectively. The results showed that, compared to R0, the grain size of the R10 sample decreased from 34.3 μm to 8.7 μm, and the dislocation density increased from 4.355 × 1014 to 9.436 × 1014 m−2. Additionally, due to the additional heat and pressure from repeated welding, the porosity decreased from 0.998% to 0.017%, the ultimate tensile strength and elongation improved from 63.5 ± 0.5 MPa and 4.5 ± 0.1% in R0 to 93.3 ± 0.5 MPa and 34.3 ± 0.1% in R10. The improvement in mechanical properties is primarily due to the combined effects of grain refinement, dislocation strengthening, and pore self-healing. This study introduces a feasible new approach for additive manufacturing of aluminum alloys and other materials that is difficult to be additively manufactured by other methods.
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