At　present,　the　emerging　solid-phase　friction-based　additive　manufacturing　technology,　including　friction　rolling　additive　manufacturing　(FRAM),　can　only　manufacture　simple　single-pass　components.　In　this　study,　multi-layer　multi-pass　FRAM-deposited　aluminum　alloy　samples　were　successfully　prepared　using　a　non-shoulder　tool　head.　The　material　flow　behavior　and　microstructure　of　the　overlapped　zone　between　adjacent　layers　and　passes　during　multi-layer　multi-pass　FRAM　deposition　were　studied　using　the　hybrid　6061　and　5052　aluminum　alloys.　The　results　showed　that　a　mechanical　interlocking　structure　was　formed　between　the　adjacent　layers　and　the　adjacent　passes　in　the　overlapped　center　area.　Repeated　friction　and　rolling　of　the　tool　head　led　to　different　degrees　of　lateral　flow　and　plastic　deformation　of　the　materials　in　the　overlapped　zone,　which　made　the　recrystallization　degree　in　the　left　and　right　edge　zones　of　the　overlapped　zone　the　highest,　followed　by　the　overlapped　center　zone　and　the　non-overlapped　zone.　The　tensile　strength　of　the　overlapped　zone　exceeded　90%　of　that　of　the　single-pass　deposition　sample.　It　is　proved　that　although　there　are　uneven　grooves　on　the　surface　of　the　overlapping　area　during　multi-layer　and　multi-pass　deposition,　they　can　be　filled　by　the　flow　of　materials　during　the　deposition　of　the　next　layer,　thus　ensuring　the　dense　microstructure　and　excellent　mechanical　properties　of　the　overlapping　area.　The　multi-layer　multi-pass　FRAM　deposition　overcomes　the　limitation　of　deposition　width　and　lays　the　foundation　for　the　future　deposition　of　large-scale　high-performance　components.