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An Overview of Viable Unconventional Processing Methods for Advanced Materials
Published in T. S. Srivatsan, T. S. Sudarshan, K. Manigandan, Manufacturing Techniques for Materials, 2018
Subramanian Jayalakshmi, Ramachandra Arvind Singh, Rajashekhara Shabadi, Jayamani Jayaraj, Sambasivam Seshan, Manoj Gupta
Friction stir processing was developed based on friction stir welding, which is a solid-state joining process. It is an emerging metalworking technique that can provide localized modification and control of microstructure at the near-surface region of metallic components. During friction stir processing, a rotating tool with a shoulder and a pin is plunged into the surface of a work piece (desired base matrix) and moved along the length and breadth of the surface to be processed (Figure 9.34) (Gan et al. 2010; Lee et al. 2006a; Mahoney and Lynch 2016; Nithin Viswanath et al. 2016; Weglowski and Pietras 2011). To produce a composite surface, the surfaces are grooved and filled with the reinforcement powder, which are then processed by the passing friction stir processing tool (Gan et al. 2010; Lee et al. 2006a; Mahoney and Lynch 2016; Nithin Viswanath et al. 2016; Weglowski and Pietras 2011). As the tool rotates, it moves forward to process the region of interest. Friction stir processing causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity in the processed zone. This technique has been successfully used (i) to produce fine-grained structures, (ii) to achieve phase modification, (iii) for surface alloying, and (iv) for the synthesis of surface micro/nanocomposites. In most friction stir processed surfaces, the surface grain structure is altered (either by friction stir processing alone or through the addition of reinforcements during friction stir process to produce surface composites). As a consequence, improvement in properties such as greater resistance to wear, fatigue, and corrosion can be realized.
Material Systems Processed by FSP
Published in B. Ratna Sunil, Surface Engineering by Friction-Assisted Processes, 2019
Wide varieties of materials have been processed by FSP to develop surface modified structures. Aluminum, magnesium, titanium, copper, and steels are the most important group of materials processed by friction stir processing. This chapter presents the work done in FSP of different materials.
Friction stir processing combined with incremental forming effect on AA2014-T6
Published in Materials and Manufacturing Processes, 2021
Jacob John, S. P. Shanmuganatan, M. B. Kiran, V. S. Senthil Kumar, R. Krishnamurthy
Friction stir processing is a prospective surface embattlement technique used in materials like aluminum and its alloys for enhancing its structural properties find versatile applications in the transport industries such as aviation and automotive sectors. Incremental mode of sheet forming is a relatively unique system of procedure that proffering agility with the reduction in cost, eliminating the need for dies thus congregating the ever-growing need for small voluminous production. In the recent past, deploying the alloys of aluminum in automobiles/aerospace sectors have reached a greater extent facilitating reduced payload capacity and fuel consumption[1,2] Among the various rarefaction mechanism proposed by researchers, FSP is one of the refinement techniques available for formability enhancement.
Comprehensive studies on processing and characterization of hybrid magnesium composites
Published in Materials and Manufacturing Processes, 2018
Friction stir processing is an evolved form of the friction stir welding process and was used earlier as a surface-reinforced composite fabrication method. Recently, research has been done to produce bulk nanocomposite using FSP by adding nanoparticles to the metal matrix. FSP is schematically illustrated in Figure 8.[145] The process essentially consists of a rotating tool with a shoulder and pin. A groove of a desirable size is initially cut on the workpiece surface and is filled with the necessary volume of reinforcement particles. Then, the rotating tool with a shoulder and pin is plunges onto the work surface. As the rotating tool moves forward, the pin (and, later, the shoulder) touches the surface of interest, thereby producing frictional heat. Due to extreme thermal softening, the material under the tool’s shoulder gets plasticized and ultimately bonded to the workpiece surface.[50,145146147148149150151] As a result of this thermos-mechanical processing on the surface of the workpiece, resultant composites have superior properties and an efficient microstructure.[149150151152153] As the process has still not reached its full capability, difficulties have been encountered by researchers regarding the uniform dispersion of reinforcements and accommodating the thickness of workpieces.
Investigation of friction stir processing effect on AA 2014-T6
Published in Materials and Manufacturing Processes, 2019
Jacob John, S.P. Shanmuganatan, M.B. Kiran, V.S. Senthil Kumar, R. Krishnamurthy
Sundaravel et al.[18] studied the optimization of tensile properties and power consumption during friction stir welding of AA5083 using grey relational analysis technique and inferred that spindle speed and tool force highly influence mechanical properties and power utilization, respectively. It is to be noted that friction stir processing is a cold processing technique involving plasticizing of material and consequent alteration of the surface structure and mechanical bonding of butt jointed material. Suganya et al.[19] produced reinforced 90/10 copper–nickel surface composites with different carbide-based ceramic particles through FSP. They concluded that process exhibits significant effect on microhardness and surface enhancement.