Critical Assessment 25: Friction stir processing, potential and problems

Gerlich, A.P.

doi:10.1080/02670836.2017.1300420

Cited by 31 publications

(7 citation statements)

References 82 publications

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“…In recent years, the demand of light weight structural materials with better properties and performance has triggered material processing industries to modify or change required properties of the base material (BM). Friction stir processing (FSP) is a promising solid-state material processing technique to improve the microstructure and properties of the material [1][2][3]. It uses a non-consumable rotating tool, which plunges into the BM and advances in the processing direction to create sever plastic deformation in BM.…”

Section: Introductionmentioning

confidence: 99%

Through-thickness microstructure and mechanical properties in stationary shoulder friction stir processed AA7075

Patel

Liu

et al. 2019

Materials Science and Technology

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Stationary shoulder friction stir processing of high strength thick AA7075 aluminium alloy demonstrated tiny gradient in the microstructure refinement across the thickness, which was attributed to the less heat input and small temperature gradient by the stationary shoulder. Stationary shoulder produced a very smooth surface finish with a little amount of flash throughout the processing area. Probe-dominated stir zone (SZ) resulted in uniform grain refinement as well as hardness distribution across the SZ thickness. The ductility in SZ increased by 48% in comparison to the unprocessed material without costing tensile strength. This tensile behaviour trend maintained throughout the thickness in SZ. GRAPHICAL ABSTRACT

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Section: Introductionmentioning

confidence: 99%

Through-thickness microstructure and mechanical properties in stationary shoulder friction stir processed AA7075

Patel

Liu

et al. 2019

Materials Science and Technology

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“…Known commercially as MELD [12,13], AFSD utilizes a hollow, rotating tool through which the feed material is delivered in the form of a powder or solid rod [14]. The rotation of the tool generates heat through friction at the interfaces between the filler, substrate, and tool [8,15]. The filler material bonds with the substrate through plastic deformation, and is deposited as a single layer as the tool is traversed across the surface.…”

Section: Introductionmentioning

confidence: 99%

Repair of Aluminum 6061 Plate by Additive Friction Stir Deposition

Martin

Luccitti

Walluk

2021

Preprint

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The deposition of new alloy to replace a worn or damaged surface layer is a common strategy for repairing or remanufacturing structural components. For high-performance aluminum alloys common in the automotive, aerospace, and defense industries, however, traditional fusion-based deposition methods can lead to solidification cracking, void formation, and loss of strength in the heat affected zone. Solid state methods, such as additive friction stir deposition (AFSD), mitigate these challenges by depositing material at temperatures below the melting point. In this work, a solid state volumetric repair was performed using AFSD of aluminum alloy 6061-T6 to fill grooves machined into the surface of a plate of 6061-T651. The groove-filling process is relevant to replacement of cracked or corroded material after removal by localized grinding. Three groove geometries were evaluated by means of metallographic inspection, tensile testing, and fatigue testing. For the process conditions and groove geometries used in this study, effective repairs were achieved to a depth of 3.1 – 3.5 mm. Below that depth, the interface between the substrate and AFSD filler exhibited poor bonding associated with insufficient shear deformation. The mechanical properties of the filler alloy, the depth of the heat affected zone, and areas for further optimization are discussed within the context of precipitation hardened aluminum alloys.

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“…Nowadays, Friction stir processing has been adopted to cater for the complex methods of surface modification. Friction stir processing (FSP) was initially derived in 1999 from the work of (Gerlich, 2017;Mishra & Ma, 2005;Mishra et al, 2014) which took its root from a novel technique called friction stir welding (FSW) that was invented in 1991 and patented by the welding institute (TWI) of UK as a solid-state joining method. Afterwards, a large number of research papers have been published for investigating the mechanical properties, microstructure and quality of FSW and FSP components (Narasimharaju & Sankunny 2019;Kundu & Singh 2017;Jian et al 2018;Aliha et al 2016;Taheri-Behrooz et al 2018;Torabi et al 2018;Akbari et al2017Behnagh et al 2012;Shahraki et al 2013;Asadi et al 2012).…”

Section: Introductionmentioning

confidence: 99%

Tribological, structural and mechanical characteristics of friction stir processed aluminium-based matrix composites reinforced with stainless steel micro-particles

et al. 2020

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The efficacy of stainless-steel micro-particles on friction stir processed aluminium-based matrix composite (ABMC) was studied using tribological, mechanical and structural analysis tools. The stainless-steel powder (17-4PH) of average size 45-90 µm was used as the reinforcement particle. The parametric values employed during the fabrication of ABMC-AA7075-T651/17-4PH were the rotational speed of 1500 rpm and travel speed of 20 mm/min while the plunge depth and tilt angles used were respectively 0.3 mm and 3 degrees. Tribological study was carried out under the influence of dry sliding condition with varying loads of 20 N and 50 N using tribometer while the scanning electron microscope (SEM) was used to capture the wear track. Structural analysis was examined with the aid of x-ray diffraction (XRD). The tensile strengths of the fabricated ABMC were also tested and the fracture surfaces were studied using SEM analysis. The results from the study revealed that at higher loading of 50 N, the wear performance was significantly improved for the fabricated aluminium composite-AA7075-T651/17-4PH when compare with lower loading of 20 N. The tensile properties for the ABMC were also improved under the influence of the stainless steel microparticles. There was structural improvement in ABMC wherein the value for crystallite size was lowest while micro-strain, dislocation density, as well as full width at half maximum (FWHM), had the highest values over the FSPed AA7075-T651 and the parent material. The examined fractured surface of the fabricated composite was dominated with fine, network and equiaxed dimples with cup and cone attributes confirming superb interfacial bonding and that the failure mode was ductile.

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Critical Assessment 25: Friction stir processing, potential and problems

Cited by 31 publications

References 82 publications

Through-thickness microstructure and mechanical properties in stationary shoulder friction stir processed AA7075

Through-thickness microstructure and mechanical properties in stationary shoulder friction stir processed AA7075

Repair of Aluminum 6061 Plate by Additive Friction Stir Deposition

Tribological, structural and mechanical characteristics of friction stir processed aluminium-based matrix composites reinforced with stainless steel micro-particles

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