This study explored solid-state additive friction stir deposition (AFSD) as a modular manufacturing technology, with the aim of enabling a more rapid and streamlined on-site fabrication process for large meter-scale nuclear structural components with fully dense parts. Austenitic 316 stainless steel (SS) is an excellent candidate to demonstrate AFSD, as it is a commonly-used structural material for nuclear applications. The microstructural evolution and concomitant changes in mechanical properties after 5 MeV Fe++ ion irradiation were studied comprehensively via transmission electron microscopy and nanoindentation. AFSD-processed 316 SS led to a fine-grained and ultrafine-grained microstructure that resulted in a simultaneous increase in strength, ductility, toughness, irradiation resistance, and corrosion resistance. The AFSD samples did not exhibit voids even at 100 dpa dose at 600 °C. The enhanced radiation tolerance as compared to conventional SS was reasoned to be due to the high density of grain boundaries that act as irradiation-induced defect sinks
