Friction stir processing technology: A review
01 Feb 2008-Metallurgical and Materials Transactions A-physical Metallurgy and Materials Science (Springer US)-Vol. 39, Iss: 3, pp 642-658
TL;DR: Friction stir welding (FSW) is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components.
Abstract: Friction stir processing (FSP), developed based on the basic principles of friction stir welding (FSW), a solid-state joining process originally developed for aluminum alloys, is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components. The FSP causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity of the processed zone. The FSP technique has been successfully used for producing the fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite and intermetallic compound in situ. In this review article, the current state of the understanding and development of FSP is addressed.
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TL;DR: A comprehensive review of surface composites via friction stir processing is presented in this article, where the underlying mechanisms in strengthening of FSP-processed surface composite are discussed with reported models.
408 citations
Cites methods from "Friction stir processing technology..."
...Initially, SP was used for producing superplastic aluminum alloys with ultra ne grain size and high grain boundary misorientations (Mishra t al., 1999; Ma, 2008)....
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TL;DR: Current and emerging joining technologies are reviewed according to the mechanisms of joint formation, i.e.; mechanical, chemical, thermal, or hybrid processes.
Abstract: Emerging trends in manufacturing such as light weighting, increased performance and functionality increases the use of multi-material, hybrid structures and thus the need for joining of dissimilar materials. The properties of the different materials are jointly utilised to achieve product performance. The joining processes can, on the other hand be challenging due to the same different properties. This paper reviews and summarizes state of the art research in joining dissimilar materials. Current and emerging joining technologies are reviewed according to the mechanisms of joint formation, i.e.; mechanical, chemical, thermal, or hybrid processes. Methods for process selection are described and future challenges for research on joining dissimilar materials are summarized.
407 citations
TL;DR: In this article, a comprehensive understanding of the fundamentals of the microstructural evolution during FSW/P has been developed, including the mechanisms underlying the development of grain structures and textures, phases, phase transformations and precipitation.
390 citations
TL;DR: In this paper, a review of the control strategies for back support, weld thinning, and keyhole defects in friction stir welding (FSW) is presented, which are basically divided into self-supported FSW, non-weld-thinning FSW and friction stir-based remanufacturing.
350 citations
TL;DR: Friction stir welding (FSW) has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys, however, it has not been entirely successful in the manufacturing of different desired materials essential to meet the sophisticated green globe requirements as discussed by the authors.
347 citations
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30 Mar 2007TL;DR: Friction stir welding (FSW) is a relatively new solid-state joining process that is used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding as discussed by the authors.
Abstract: Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this review article, the current state of understanding and development of the FSW and FSP are addressed. Particular emphasis has been given to: (a) mechanisms responsible for the formation of welds and microstructural refinement, and (b) effects of FSW/FSP parameters on resultant microstructure and final mechanical properties. While the bulk of the information is related to aluminum alloys, important results are now available for other metals and alloys. At this stage, the technology diffusion has significantly outpaced the fundamental understanding of microstructural evolution and microstructure–property relationships.
4,750 citations
TL;DR: The mechanical properties of nanocrystalline materials are reviewed in this paper, with emphasis on their constitutive response and on the fundamental physical mechanisms, including the deviation from the Hall-Petch slope and possible negative slope, the effect of porosity, the difference between tensile and compressive strength, the limited ductility, the tendency for shear localization, fatigue and creep responses.
3,828 citations
TL;DR: In this article, a review examines recent developments related to the use of ECAP for grain refinement including modifying conventional ECAP to increase the process efficiency and techniques for up-scaling the procedure and for the processing of hard-to-deform materials.
3,669 citations
TL;DR: In this paper, the grain structure, dislocation density and second phase particles in various regions including the dynamically recrystallized zone (DXZ), thermo-mechanically affected zone (TMAZ), and heat-affected zone (HAZ) of a friction stir weld aluminum alloy 7050-T651 were investigated and compared with the unaffected base metal.
934 citations
TL;DR: Friction stir welding (FSW) was used to weld 7075 T651 aluminum, an alloy considered essentially unweldable by fusion processes as discussed by the authors, which exposed the alloy to a short time, high-temperature spike, while introducing extensive localized deformation.
Abstract: Friction stir welding (FSW), a new welding technique invented at TWI, was used to weld 7075 T651 aluminum, an alloy considered essentially unweldable by fusion processes. This weld process exposed the alloy to a short time, high-temperature spike, while introducing extensive localized deformation. Studies were performed on these solid-state welds to determine mechanical properties both in the longitudinal direction, i.e., within the weld nugget, and, more conventionally, transverse to the weld direction. Because of the unique weld procedure, a fully recrystallized fine grain weld nugget was developed. In addition, proximate to the nugget, both a thermomechanically affected zone (TMAZ) and heat affected zone (HAZ) were created. During welding, temperatures remained below the melting point and, as such, no cast or resolidification microstructure was developed. However, within the weld nugget, a banded microstructure that influences room-temperature fracture behavior was created. In the as-welded condition, weld nugget strength decreased, while ductility remained high. A low-temperature aging treatment failed to fully restore T651 strength and significantly reduced tensile ductility. Samples tested transverse to the weld direction failed in the HAZ, where coarsened precipitates caused localized softening. Subsequent low-temperature aging further reduced average strain to failure without affecting strength. Although reductions in strength and ductility were observed, in comparison to other weld processes, FSW offers considerable potential for welding 7075 T651 aluminum.
864 citations