Friction Stir Additive Manufacturing: Route to High Structural Performance

Palanivel, S.; Sidhar, Harpreet; Mishra, Rajiv S.

doi:10.1007/s11837-014-1271-x

Cited by 130 publications

(51 citation statements)

References 8 publications

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“…Figures 5(a) and 5(e) shows the macrograph of Mg (WE43) and Al alloy (AA5083) builds fabricated using FSAM (Palanivel et al, 2015a(Palanivel et al, , 2015b. As shown in Figure 5 and summarised in Table 1, excellent mechanical properties were reported in these builds.…”

Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 94%

“…In addition to reducing cost and saving energy, recent studies by Palanivel et al (2015aPalanivel et al ( , 2015b) demonstrated FSAM as a technique for producing high performing structures. Chamanfar et al (2015), Dilip et al (2012), Gandra et al (2014), Kandasamy et al (2013a) and Palanivel et al (2015a) The basic working principle of FSAM is similar to friction stir welding.…”

Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 99%

“…Detailing the exact role of these variables is out of the scope of this article and the reader is encouraged to refer to the textbook by Mishra et al on friction stir welding (Mishra et al, 2014). The cross-sectional macrograph and hardness profile along the build direction in an AA5083 alloy manufactured using 500 rpm and 152 mm/min (Palanivel et al 2015a(Palanivel et al , 2015b) (see online version for colours)…”

Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 99%

“…Best suited for rapid fabrication of large scale parts from simple structural blocks, gradient structures, airframe brackets, small protruding features, strengthening elements, L frame clips for aerospace FSAM (Baumann, 2012;Leque et al, 2006;Palanivel et al,2015b) Manufacturing preforms Fabricating stringer on skin in aircraft fuselage, stiffeners for other high performance applications: ex: creep resistance for fossil and nuclear applications, gradient materials AFS (Calvert, 2015;Kandasamy et al, 2013aKandasamy et al, , 2013b Large scale fabrication of ultrafine grained functionally graded Mg armor…”

Section: Current Applications Potential Applicationsmentioning

confidence: 99%

See 3 more Smart Citations

Building without melting: a short review of friction-based additive manufacturing techniques

Palanivel¹,

Mishra²

2017

IJASMM

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Fusion additive technologies have pushed the boundaries beyond what was previously envisaged in the metal community. Championed by laser-based and electron beam technologies, metal additive manufacturing has captivated the interests of aerospace, defence, energy, automotive, and medical sectors. Though game-changing, these fusion-based techniques suffer from solidification related issues which play a critical role in applications where high premium is placed on materials' performance. Furthermore, only limited number of alloys can be built due to complexities associated with melting. To address these drawbacks, parallel work on solid state technologies was initiated in the last decade. An outcome of these efforts has been the development of additive manufacturing technologies based on friction which has now reached a stage where compilation is possible. In this article, fundamental principle and features of these friction-based additive technologies are reviewed with special emphasis on their individual advantages and differences between them. In addition, further scope, challenges and potential of these technologies are highlighted.Keywords: fusion additive technologies; metal additive manufacturing; solid state; friction-based additive manufacturing; FBAM; material performance. After undergraduate studies, he joined the Center for Friction Stir Processing and works with Dr. Rajiv Mishra. His research interests include additive manufacturing, physical metallurgy of Al and Mg alloys, alloy design using Calphad approach and field effects on microstructure. In the field of additive manufacturing, he has the first few publications on friction stir additive manufacturing and has also published on fusion additive manufacturing linking site dependent properties to microstructure.

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Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 94%

Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 99%

Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 99%

Section: Current Applications Potential Applicationsmentioning

confidence: 99%

See 2 more Smart Citations

Building without melting: a short review of friction-based additive manufacturing techniques

Palanivel¹,

Mishra²

2017

IJASMM

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“…Multi-track FSLW has potential to fabricate large-scale aluminum monolithic components. It is also the key technology for the friction stir additive manufacturing (FSAM), which is an important direction for the development of friction stir technology [10][11][12]. On the other hand, the tilt angle is normally adopted in these reports about FSLW, because tilt angle is widely believed to be an important processing parameter to obtain defect-free joint for friction stir technologies [13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties

Zou

Liu

et al. 2016

Metals

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Friction stir lap welding (FSLW) raises the possibility of fabricating high-performance aluminum components at low cost and high efficiency. In this study, we mainly applied FSLW to fabricate multi-track 2024 aluminum alloy without using tool tilt angle, which is important for obtaining defect-free joint but significantly increases equipment cost. Firstly, systematic single-track FSLW experiments were conducted to attain appropriate processing parameters, and we found that defect-free single-track could also be obtained by the application of two-pass processing at a rotation speed of 1000 rpm and a traverse speed of 300 mm/min. Then, multi-track FSLW experiments were conducted and full density multi-track samples were fabricated at an overlapping rate of 20%. Finally, the microstructure and mechanical properties of the full density multi-track samples were investigated. The results indicated that ultrafine equiaxed grains with the grain diameter about 9.4 µm could be obtained in FSLW samples due to the dynamic recrystallization during FSLW, which leads to a yield strength of 117.2 MPa (17.55% higher than the rolled 2024-O alloy substrate) and an elongation rate of 31.05% (113.84% higher than the substrate).

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In Situ Study on Fracture Behavior of Thick‐Section Friction Stir‐Welded AA 5083 Alloy

Sarvesha,

Garcia,

Dolmetsch

et al. 2024

Adv Eng Mater

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Friction stir welding (FSW) produces a gradient microstructure with distinct metallurgical zones. The present study focuses on characterizing the fracture behavior during uniaxial loading across thick‐section FSW joint in non‐heat‐treatable 5083 aluminum alloy. The hardness variation was linked to microstructural features across the weld zones through correlative microscopy. Notably, the heat‐affected zone (HAZ) exhibits a lower hardness of 75 HV, while the thermo‐mechanically affected zone (TMAZ) and stir zones (SZ) display a hardness of around 79HV. A marginal difference in hardness in HAZ prompts strain localization in HAZ on the advancing side of the weld resulting in offset in fracture from the SZ, which is captured through in‐situ monitoring of the tensile test. Further, the post‐deformation analysis reveals crack propagation along the maximum shear stress plane due to the coalescence of micro‐voids resulting from the fracturing and debonding of second‐phase particles. Overall, this study provides valuable insight for optimizing the FSW process of AA 5083 alloy for thick‐section applications.This article is protected by copyright. All rights reserved.

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Friction Stir Additive Manufacturing: Route to High Structural Performance

Cited by 130 publications

References 8 publications

Building without melting: a short review of friction-based additive manufacturing techniques

Building without melting: a short review of friction-based additive manufacturing techniques

Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties

In Situ Study on Fracture Behavior of Thick‐Section Friction Stir‐Welded AA 5083 Alloy

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