Systems, devices, and methods for surface preparation for bond enhancement in additive deposition processes

An additive friction stir deposition device comprising:

• a shoulder configured to rotate about a central axis, the shoulder comprising a channel extending from a first end of the shoulder to a second end of the shoulder, the channel configured to allow a filler material to pass through the shoulder from the first end towards the second end, the shoulder further configured to deposit the filler material as the device is advanced along a deposition surface;
• a wire brush skirt configured to co-rotate with the shoulder and contact the deposition surface as the device is advanced along the deposition surface;
• and
• a gas shroud configured to direct pressurized gas toward the deposition surface and remove contaminants as the device is advanced along the deposition surface.

A method of additive friction stir deposition comprising:

• advancing an additive friction stir deposition device along a deposition surface;
• contacting the deposition surface with a wire brush skirt configured to co-rotate with a rotating shoulder of the device;
• removing contaminants from the deposition surface by directing a pressurized gas toward the deposition surface;
• and
• depositing a filler material from a channel extending through the rotating shoulder to the deposition surface.