Surface composites by friction stir processing: A review

Friction stir based welding and processing technologies - processes, parameters, microstructures and applications: A review

Functionally graded materials (FGMs) are a broad research area and attract considerable tremendous attention today in the materials science and engineering society. In recent years, FGMs have experienced remarkable developments in manufacturing methods. FGMs can be produced using several well-known processing techniques from conventional to advanced. This research provides an overview of manufacturing methods for FGMs, thus describing the fundamental difficulties and strengths of these methods based on the available literature over 30 years. Besides, this critical review gives a comprehensive summary of the various applications and the future trends for research required for the design and production of these materials properly with a smooth graded. The anticipated findings of the current paper can be considered as a milestone for future production and analysis investigations for FGMs and are beneficial for researchers, designers, and manufacturers in this scope.

30 Years of functionally graded materials: An overview of manufacturing methods, Applications and Future Challenges

Driven by increasing costs for energy and raw material and especially by the European CO2-emission laws, automotive industry faces the challenge to develop more lightweight and at the same time still rigid and crash-stable car bodies, that are affordable for large-scale production. The implementation of weight-reduced constructions depends not only on the availability of lightweight materials and related forming technologies, but also on cost-efficient and reliable joining technologies suitable for multi-material design. This article discusses the challenges and requirements for these technologies, based on the example of joining aluminium with press-hardened boron steels, what is considered as a very important material combination for affordable future lightweight mobility. Besides a presentation of recent developments for extending the process limits of conventional mechanical joining methods, new promising technologies such as resistance element welding are introduced. In addition, the performance, advantages, and disadvantages of the presented technologies are compared and discussed.

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Innovative and Highly Productive Joining Technologies for Multi-Material Lightweight Car Body Structures

Friction surfacing—A review

Performance analysis of friction surfacing

Wear characterization of functionally graded Al–SiC composite coatings produced by Friction Surfacing

This paper aims to study the effect of overlapping direction in multipass friction stir processing (FSP). An AA 5083-H111 alloy 8 mm thick was tested. Structural and mechanical differences were observed when overlapping by the advancing side (AS) direction or by the retreating side (RS) one. The surface morphology was analysed and the processed zone was observed by optical microscopy, hardness measurements and bending tests were performed to evaluate surface ductility. Overlapping by the retreating side was found to generate smoother surfaces, while overlapping by the advancing side led to more uniform thickness layers. Hardness within the processed layer increased by 8.5% and was seen to be approximately constant between passes. The mechanical resistance and toughness under bending were improved by 18% and 19%, respectively.

Effect of overlapping direction in multipass friction stir processing

Friction Surfacing is a solid state coating technique with applications in the rehabilitation of worn parts, hardfacing or corrosion protection. It is suitable to process aluminium alloys as it does not require the fusion of neither the coating nor the substrate, relying on a solid state diffusion bonding mechanism. The present study addresses the use of friction surfacing to deposit AA6082-T6 on AA2024-T3, with emphasis on tensile, bending and wear characterization. The thermo-mechanical transformations experienced by the materials during processing were also investigated. Sound aluminium coatings were produced featuring a sound bonding with no porosity or intermetallic formation at the interface. The coated specimens present an ultimate tensile strength 25 % lower than the substrate AA 2024-T3 base material while the strain at break was improved in 42 %. Although the coating edges were seen to be prone to delamination, coating fracture did not precede substrate fracture. An improved coating wear performance was observed due to the microstructural features identified under SEM, namely a micrometric sub-grain structure.

João Gandra

Papers

Friction surfacing—A review

Performance analysis of friction surfacing

Wear characterization of functionally graded Al–SiC composite coatings produced by Friction Surfacing

Effect of overlapping direction in multipass friction stir processing

Deposition of AA6082-T6 over AA2024-T3 by friction surfacing - Mechanical and wear characterization