Friction stir consolidation of aluminum machining chips

Li, Xiao; Baffari, Dario; Reynolds, Anthony P.

doi:10.1007/s00170-017-1016-4

Cited by 55 publications

(25 citation statements)

References 21 publications

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“…SPD processes commonly used for SSR are: Equal channel angular pressing (ECAP) [12,13], cyclic extrusion compression (CEC) [14], and high pressure torsion (HPT) [15]. Lately, new and promising methods for SSR are arising such as friction stir extrusion (FSE) [16] and friction stir consolidation (FSC) [17]. Tang et al [16] utilized FSE to produce aluminum AW 2050 and AW 2195 defect free wires from the machining chips, with good combination of the microhardness and bend ductility.…”

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confidence: 99%

Statistical Analysis of the Combined ECAP and Heat Treatment for Recycling Aluminum Chips Without Remelting

Krolo

Lela

Dumanić

et al. 2019

Metals

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The main aim of this paper is to present an environmentally friendly method for aluminum recycling. Development of new recycling technologies in order to increase scrap reuse potential and CO 2 emission savings are of the main importance for aluminum circular economy. In this paper, aluminum chips waste was recycled without any remelting phase in order to increase energy and material savings. The presented process is usually called solid state recycling or direct recycling. Solid state recycling process consists of chips cleaning, cold pre-compaction and hot direct extrusion followed by a combination of equal channel angular pressing (ECAP) and heat treatment. Influence of holding time during solid solution treatment and both artificial aging time and temperature on mechanical properties of the recycled EN AW 6082 aluminum chips were investigated. A comprehensive number of the experiments were performed utilizing design of experiments approach and response surface methodology. Regression models were developed for describe the influence of heat treatment parameters for presented solid state recycling process on mechanical properties of the recycled samples. Utilizing novel procedure high quality recycled samples were obtained with mechanical properties comparable with commercially produced EN AW 6082 aluminum alloy in T6 temper condition. Metallographic analysis of the recycled samples was also performed.In order to reduce the negative effect on the environment, various authors recognized solid state recycling (SSR) as a possible alternative to the conventional aluminum recycling process [4][5][6][7][8][9]. When SSR is employed, material losses are much smaller because the remelting phase is completely avoided. Aluminum is a highly reactive material and it has a tendency to form aluminum oxide on its surface. This is even more pronounced for lightweight aluminum scrap due to its high surface to mass ratio. During the remelting process this oxide is floating on the melt surface mixed with dross. Therefore, aluminum lightweight scrap (chips, foils, and sheet skeletons) is problematic when conventional recycling technology is used because up to 20% of the aluminum can be lost due to the mixing with dross and burning [9]. According to previous research papers concerned with SSR process, it is possible for material yield to be over 90% when this type of recycling is employed, while energy consumption can be only 10% compared to conventional recycling process that uses remelting [6][7][8]. Furthermore, manufacturing profiles from solid state bonded chips gives a 96% saving in CO 2 emission compared to production from billets made by conventional recycling of aluminum manufacturing waste [8]. In order to produce SSR samples with appropriate quality, the combination of the high temperature, normal stress, shear stress, and plastic deformation should be achieved [6,7]. Therefore, the most used process for SSR is direct hot extrusion, but lately severe plastic deformation (SPD) processes opened new possibilities [10]. SPD i...

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confidence: 99%

Statistical Analysis of the Combined ECAP and Heat Treatment for Recycling Aluminum Chips Without Remelting

Krolo

Lela

Dumanić

et al. 2019

Metals

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“…The non-homogeneous mechanical properties of consolidated billet during single-step FSC of aluminum alloy AA6061 were first reported by Li et al [36]. They found that the main reason for inhomogeneity was different plastic deformation and the temperature of the material in the radial direction and the advancing direction of the die.…”

Section: Introductionmentioning

confidence: 90%

A novel approach to enhance mechanical properties during recycling of aluminum alloy scrap through friction stir consolidation

Latif

Ingarao

Gucciardi

et al. 2021

Int J Adv Manuf Technol

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Solid state recycling (SSR) is a new approach for making metals recycling more efficient with respect to remelting-based approaches. Friction stir consolidation (FSC) is a new solid-state process that is employed to recycle metallic scraps. Until now, a single-step FSC process was applied to recycled metal chips. During the single-step approach, critical processes parameters, especially processing time and rotational speed, are considered vital to control the quality and mechanical properties of the billet. However, the effectiveness of process parameters is highly restricted by challenging masses of recycling chips and machine competency. The present study first highlights the issues of the single-step FSC process, such as unconsolidated billet and poor mechanical properties at the bottom of the part, i.e., far away from the stirring action. Then, for the first time, three different two-step FSC methods were introduced as new approaches to overcome the existing challenges of the single-step method. The effectiveness of these methods was evaluated through the Vickers hardness measurements, and microstructure analysis. The results showed that two-step FSC methods successfully led to a fully consolidated billet and considerably improved mechanical properties.

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“…AA5052 alloy is a common aluminum alloy with medium strength and usually used in a wide variety of structures like in boat hulls, gangplanks, and other products exposed to marine environments [11]. Machining chips with uniform size as precursors and desired thickness were collected by dry milling of the solid block metal using a milling machine model of FU281, and Equation 1 [13] was used to determine the desired chip thickness from initial 8mm diameter solid block.…”

Section: Methodsmentioning

confidence: 99%

Friction Stir Consolidation of Aluminum AA5052 Alloy Machining Wastes

Abebe¹,

Wolla²

2021

Preprint

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The purpose of this paper is to develop aluminum AA5052 alloy solid disc from machining wastes via friction stir consolidation (FSC) process & optimize its parameters: die rotational speed, pre-compact aspect ratio and processing time for better performance characteristics. At first, the required dedicated tooling are designed and built for the specific process. Then, the solid discs are fabricated from aluminum AA5052 alloy machining chips through FSC process in which the experimental parameters considered are rotational speed (315, 400 and 500 rpm), pre-compact aspect ratio (25.4/7, 25.4/5 and 25.4/3) and processing time (30, 45 and 60 sec). Based on the experiment, the compressive strength, hardness and microstructure of the consolidated solid disc are evaluated. Taguchi’s L9 orthogonal array is used to analyze and optimize the process. The results revealed that solid disc is successfully fabricated using FSC process using dedicated tooling, and rotational speed (500 rpm), compact aspect ratio (25.4/3) and processing time (60 sec) are optimal FSC processing conditions. The microsturcture of the solid disk shows finer and fully recrystallized grains in axial cross section orientation of the disc particularly in the central region. Moreover, the results show, the compressive strength and hardness of the solid disc are comparable to that of forged or cast disc and suitable for most engineering structural applications.

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Friction stir consolidation of aluminum machining chips

Cited by 55 publications

References 21 publications

Statistical Analysis of the Combined ECAP and Heat Treatment for Recycling Aluminum Chips Without Remelting

Statistical Analysis of the Combined ECAP and Heat Treatment for Recycling Aluminum Chips Without Remelting

A novel approach to enhance mechanical properties during recycling of aluminum alloy scrap through friction stir consolidation

Friction Stir Consolidation of Aluminum AA5052 Alloy Machining Wastes

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