Functionalized material production via multi-stack Upward Friction Stir Processing (UFSP)

Inácio, Patrick L.; Nogueira, Fabio S.; Ferreira, Francisco B.; Vidal, Catarina; Schell, Norbert; Tero, Teemu; Vilaça, Pedro; Oliveira, J.P.; Santos, Telmo G.

doi:10.1080/10426914.2021.1942909

Cited by 12 publications

(10 citation statements)

References 46 publications

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“…The results showed that variations in microhardness values across the three planes were not significant and that AA6082-T651 had an average hardness of 118 HV0.5. The characterization of the other metallic alloy (AA 7075-T651) was carried out by the authors in previous works [42,43]. Table 2 shows the mechanical, electrical, and thermal properties of the two base materials used in this work.…”

Section: Methodsmentioning

confidence: 99%

“…The SiC particles had nonuniform shapes and sizes ranging between 4 and 20 µm, with an average diameter of Coatings 2023, 13, 962 4 of 18 6 µm [45]. Figure 1 shows the morphology and dimensions of the SiC particles observed through scanning electron microscopy (SEM) [42]. During the experimental tests, reinforcement particles were incorporated onto the surface of the metallic alloys to produce a surface composite.…”

Section: Methodsmentioning

confidence: 99%

“…Tool wear is also a significant issue when using hard abrasive particles to reinforce aluminium-based matrices. So, a new FSP-based technique developed by Inácio et al [42] called UFSP was proposed, which promotes an upward viscoplastic material flow to pull up functional particles from the bottom of the tool probe to its top, resulting in a more uniform and three-dimensional distribution of particles in the metal matrix. Various characterization techniques were employed in this study, including macrography and micrography analyses, scanning electron microscopy (SEM) and X-ray energy-dispersive spectrometer (EDS) analyses, and microhardness and eddy currents measurements.…”

Section: Introductionmentioning

confidence: 99%

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Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

et al. 2023

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Surface metal matrix composites offer an excellent solution for applications where surface properties play a crucial role in components’ performance and durability, such as greater corrosion resistance, better wear resistance, and high formability. Solid-state processing techniques, such as friction surfacing and friction stir welding/processing, offer several advantages over conventional liquid-phase processing methods. This research investigated the feasibility of producing surface composites of aluminium-based dissimilar alloys reinforced with functional microparticles through experimental validation, determined the process parameters that resulted in a more homogeneous distribution of the particles in the surface composites, and enhanced the understanding of Upward Friction Stir Processing (UFSP) technology. The production of aluminium-based dissimilar alloys (AA 7075-T651 and AA 6082-T651) surface composites reinforced with SiC particles was studied, and it was concluded that the macrography and micrography analyses, scanning electron microscopy (SEM) analysis, microhardness measurements, and eddy currents technique reveal an extensive and homogeneous incorporation of SiC particles. In the stirred zone, a decrease of approximately 20 HV 0.5 in hardness was observed compared to the base material. This reduction is attributed to the weakening effect caused by low-temperature annealing during UFSP, which reduces the strengthening effect of the T651 heat treatment. Additionally, the presence of particles did not affect the surface composite hardness in the stirred zone. Furthermore, despite the presence of significant internal defects, SEM analyses revealed evidence of the lower alloy merging with the upper zone, indicating that the lower plate had a role beyond being merely sacrificial. Therefore, the production of bimetallic composites through UFSP may offer advantages over composites produced from a monometallic matrix. The results of the eddy currents testing and microhardness measurements support this finding and are consistent with the SEM/EDS analyses.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

et al. 2023

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“…Furthermore, FSP parameters (tool rotation and transverse speeds, tilt angle, tool geometries, etc.) are the other major influencing factors controlling surface composites' final microstructure and properties [25][26][27]. The tool rotation speeds from 400 to 2000 rev min −1 and transverse speed from 20 to 100 mm min −1 during FSP are commonly used for Mg alloys.…”

Section: Introductionmentioning

confidence: 99%

“…[22][23][24]. Recently, a novel FSP technique (upward FSP) has been introduced with the successful processing of SiC particles into an aluminium alloy (AA7075-T651) [25]. The processed matrix exhibited more uniform dispersion of foreign particles.…”

Section: Introductionmentioning

confidence: 99%

Development of WE43/TiC surface composites using friction stir processing: A parametric study

Kang

Singh

Singla³

2023

Materials Science and Technology

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Surface composites of WE43 Mg alloy reinforced with TiC nanoparticles were successfully fabricated using friction stir processing. The effects of various tool profiles, tool rotation, and transverse speeds on the metallurgical and mechanical properties of as-received and WE43/TiC composites were comprehensively investigated. The dispersion of TiC nanoparticles was uniform throughout the stir zone. The square tool at 1700 rev min−1 rotational speed and 60 mm min−1 transverse speed produced the finest grain structure in the composites, exhibiting maximum microhardness (151.7 Hv), maximum nano-hardness (1.596 GPa), maximum elastic moduli (36.54 GPa), and minimum wear rate (0.0279 mm3 min−1). Conversely, a square tool at 800 rev min−1 and 60 mm min−1 transverse speed produced the best mechanical properties in the WE43 alloy.

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Particles’ distribution enhancing in aluminum-based composites produced by upward friction stir processing

Vidal

Ferreira

Inácio

et al. 2023

Int J Adv Manuf Technol

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A new variant of friction stir processing named upward friction stir processing (UFSP) is a promising approach to control particles’ distribution and promote a more uniform distribution over a larger processed area. This variant involves using two sheets with functional particles between them to produce metallic composites. A spacer is used to ensure the desired quantity and uniform distribution of the particles and prevent sputtering. This technique promotes an upward flow to introduce more particles with a uniform distribution in the processed volume, avoiding discrete holes or grooves. This study involved enhancing the particles’ distribution by varying process parameters. The resulting trial with the best particles’ distribution was characterized by means of light microscopy, eddy current testing, microhardness mapping, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. The study revealed that UFSP can improve the particles’ distribution in the stir zone of metallic composites, especially when multi-passes are performed towards the retreating side of the plates. The process parameters that produced an improvement in particles’ distribution were six passes with an offset of 1 mm towards the retreating side, the tool rotation and processing speed of 900 rev/min, and 180 mm/min, respectively, and a spacer’s thickness of 0.5 mm. The resulting hardness and electrical conductivity profiles show that the UFSP technique can significantly affect material’s properties, including mechanical strength, particularly when processing with tool offset towards the retreating side. Furthermore, the hardness increased by about 22% in composites produced with the addition of reinforcement particles. However, for some aluminum alloys, the properties decreased under such conditions. These findings highlight the potential of UFSP for producing functionalized materials with tailored properties, while also underscoring the importance of careful parameters selection to optimize the material´s performance. Graphical Abstract

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Functionalized material production via multi-stack Upward Friction Stir Processing (UFSP)

Cited by 12 publications

References 46 publications

Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

Development of WE43/TiC surface composites using friction stir processing: A parametric study

Particles’ distribution enhancing in aluminum-based composites produced by upward friction stir processing

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