Surface composites by friction stir processing: A review

Considerable progress has been made over the last decades in thermal spray technologies, practices and applications. However, like other technologies, they have to continuously evolve to meet new problems and market requirements. This article aims to identify the current challenges limiting the evolution of these technologies and to propose research directions and priorities to meet these challenges. It was prepared on the basis of a collection of short articles written by experts in thermal spray who were asked to present a snapshot of the current state of their specific field, give their views on current challenges faced by the field and provide some guidance as to the R&D required to meet these challenges. The article is divided in three sections that deal with the emerging thermal spray processes, coating properties and function, and biomedical, electronic, aerospace and energy generation applications.

https://link.springer.com/content/pdf/10.1007%2Fs11666-016-0473-x.pdf

The 2016 Thermal Spray Roadmap

Improved surface properties with the retainment of bulk properties are necessary for a component for enhanced wear characteristics. Friction stir processing (FSP) is used to produce such surface composites. Fabrication of 5083 aluminum alloy with reinforced layers of boron carbide (B 4 C) through FSP was carried out. Micro and nano sized B 4 C particles were used as reinforcements. The friction processed surface composite layer was analyzed through optical and scanning electron microscopical studies. The number of passes and the size of reinforcement play a vital role in the development of surface composites by FSP. Mechanical properties of the friction stir processed surface composites were evaluated through micro hardness and universal tensile tests. The results were compared with the properties of the base metal. The role of reinforcement and number of passes on properties were also evaluated. Tribological performance of the surface composites is tested through pin on disk test. The surface composite layer resulted in three passes with nano particle reinforcement exhibited better properties in hardness, tensile behavior and wear resistance compared to the behavior of the base metal.

Fabrication of Al5083/B4C surface composite by friction stir processing and its tribological characterization

https://profdoc.um.ac.ir/articles/a/1055852.pdf

Welding processes for wear resistant overlays

Increasing demand of lightweight structures with exceptional properties elicits materials processing and manufacturing technologies to tailor blanks in order to achieve or enhance those pre...

Recent Development in Friction Stir Processing as a Solid-State Grain Refinement Technique: Microstructural Evolution and Property Enhancement

The modification of a thermally sprayed cemented carbide (WC–CrC–Ni) layer by friction stir processing (FSP) was studied. The cemented carbide layer was successfully modified using a sintered cemented carbide (WC–Co) tool. The defects in the cemented carbide layer disappeared and the hardness of the cemented carbide layer increased to ∼ 2000 HV, which was about 1.5 times higher than that of the as-sprayed cemented carbide layer. Additionally, the cemented carbide layer was bonded to the SKD61 (Nominal composition: 0.35–0.42 mass% C, 0.8–1.2 mass% Si, 0.25–0.5 mass% Mn, 4.8–5.5 mass% Cr, 1.0–1.5 mass% Mo, 0.8–1.2 mass% V, balance Fe) substrate by diffusion of the metallic elements and the distortion of the coating–substrate interface producing a mechanical interlocking effect.

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Modification of thermally sprayed cemented carbide layer by friction stir processing

/pdf/modification-of-thermally-sprayed-cemented-carbide-layer-by-3m8klqvmf3.pdf

A general fabrication process of the nanostructured tool steel layer with various carbide particles was developed by a combination of laser cladding and friction stir processing (FSP). The dendritic carbides formed by the laser cladding were crushed to carbide nanoparticles during the FSP, and were uniformly dispersed in the iron matrix. The shape and size of the carbide particles could be controlled by the conditions of the laser cladding and the FSP. The nanostructured tool steel layer formed by the laser and the FSP under the optimized conditions had a microhardness of ~ 900 HV which was higher than that of conventional tool steels.

Fabrication of nanostructured tool steel layer by combination of laser cladding and friction stir processing

The microstructural control of the nitrided case on a cold-work tool steel (SKD11) plate by laser melting and friction stir processing (FSP) was studied. The laser melting and the FSP were used as a pretreatment for the nitriding to refine the microstructure of the SKD11. The diffusion zone of the nitrided case on the SKD11 plate contained thick brittle boundary lines consisting of local formed nitride particles. On the other hand, the microstructure of the diffusion zone was very uniform and the thick brittle boundary lines disappeared as a result of the combined treatment of the laser melting and the FSP before the nitriding process.

http://www.jwri.osaka-u.ac.jp/~dpt9/Nitride.pdf

Modification of nitride layer on cold-work tool steel by laser melting and friction stir processing

The present invention provides a method of forming a metal coating having a microstructure as well as a structural member having a metal coating formed by the method. In particular, the invention provides an advantageous method of forming a metal coating in which minute carbides are uniformly dispersed. The method of forming the metal coating of the present invention includes the steps of cladding a surface of the substrate with metal powder by a laser cladding method and forming the metal coating having a microstructure by applying a friction stir processing to the cladded region.

Genryu Abe

Papers

Modification of thermally sprayed cemented carbide layer by friction stir processing

Modification of thermally sprayed cemented carbide layer by friction stir processing

Fabrication of nanostructured tool steel layer by combination of laser cladding and friction stir processing

Modification of nitride layer on cold-work tool steel by laser melting and friction stir processing

Method for forming metal membrane