Different strategies of secondary phase incorporation into metallic sheets by friction stir processing in developing surface composites

Abstract

Friction stir processing (FSP) is a solid-state processing method, which recently gained wide popularity to modify the microstructure of metallic surfaces and to produce surface composites. For the past decade, composites of different materials such as aluminum, copper, magnesium, titanium, and their alloys were successfully produced by FSP. The amount of secondary phase that is dispersed at the surface of the workpiece during FSP and the level of dispersion depend on many factors such as tool design, processing parameters, and type of material. Recently, the method of secondary phase incorporation into the surface metals was also considered as an important factor in developing surface composites by FSP. A few strategies such as groove filling, holes filling, sandwich method, direct method, and surface coating followed by FSP methods have been developed as promising ways of secondary phase incorporation into the surface of the materials during FSP. The aim of this review paper is to give a comprehensive summary of different methods developed to disperse the secondary phase into the surface of the workpiece during FSP to produce surface composites. The strategies have been explained, compared, and discussed to suggest an appropriate method based on the requirement to adopt in developing surface composites.

A New Approach to Direct Friction Stir Processing for Fabricating Surface Composites

“…Furthermore, significant homogeneity in the dispersion of SiC particles into the composite matrix has been reported [36] to occur as a result of changing the tool rotational direction between passes. Other factors such as the travel speed of the rotating tool and the traverse tool speed have various effects depending on the heating cycles developed during processing, as a result of deformation processes similar to extrusion and forging [20,35,37].…”

“…Crystals 2021, 11, x FOR PEER REVIEW 8 of 15 tool speed have various effects depending on the heating cycles developed during processing, as a result of deformation processes similar to extrusion and forging [20,35,37].…”

“…An in situ surface composite was produced by smearing the aluminum surface with reinforcement SiC particles and methanol and applying FSP to produce a surface composite layer. Since then, different methods for adding reinforcement particles have been reported [4,12,[19][20][21][22][23][24]. For example, several studies proposed a new FSP method for making in situ composites, known as the groove method, by filling the reinforcement particles into a machined groove in the base material's top surface using FSP [25][26][27][28].…”

Joint quality enhancement of AA6061-T6 friction stir weldment by reinforcing with pulverized glass waste using different reinforcement strategies

“…Also, Abioye et al [10] has established a maximum groove width of 2 mm as a benchmark for producing ceramic particles-reinforced AA 6061-T6 friction stir welded joint. Apart from the creation of centre groove, creation of holes on top of the base plate (along and/or around the weld line) has been identified as another method of incorporating reinforcement particles (i.e., reinforcement strategy) in the friction stir welded joint or friction stir processed (FSP) surface [11].…”

Surface development by reinforcing nano-composites during friction stir processing – a review

“…These days, friction stir processing (FSP) is considered as a solid-state metal processing technique, which was adopted from the friction stir welding (FSW) process, but FSP is not applicable for joining the metals (Ratna Sunil, 2016; Kumar, 2016; Ma et al , 2017). FSP, when compared with the other techniques such as cladding, spraying and laser remitting, is considered to be an effective process for refining and homogenizing the grain structure.…”