• Multi-layer multi-pass FRAM successfully fabricates aluminum alloy components with complex geometries, overcoming the single-pass width limitation.
• Mechanical interlocking and recrystallization in overlapped zones enhance bonding, achieving tensile strength >90% of single-pass samples.
• Surface grooves from overlapping are filled by material flow in subsequent layers, ensuring dense microstructure and excellent mechanical properties.
• This solid-state additive method paves the way for large-scale, high-performance aluminum alloy components in aerospace and transportation.