Use of Friction Surfacing for Additive Manufacturing
05 Feb 2013-Materials and Manufacturing Processes (Taylor & Francis Group)-Vol. 28, Iss: 2, pp 189-194
TL;DR: In this paper, sound multi-layered deposits in various ferrous materials were realized using friction surfacing in both single-and multi-track approaches, and samples with fully enclosed internal cavities were also successfully produced.
Abstract: In this work, we explore the possibility of utilizing friction surfacing, an emerging solid-state surface coating process, for layer-by-layer manufacture of three-dimensional metallic parts. One possibility in this regard (single-track friction surfacing) is to utilize friction surfacing for depositing a track or layer of material (sufficiently wide to cover the entire layer area), which is subsequently shaped to its corresponding slice counter using CNC machining. Another possibility (multi-track friction surfacing) is to generate a layer from multiple overlapping tracks of friction surfaced material, which is subsequently shaped as required using CNC machining. In the current work, sound multi-layered deposits in various ferrous materials were realized using friction surfacing in both single- and multi-track approaches. Samples with fully enclosed internal cavities and those consisting of different materials in different layers were also successfully produced. The deposits showed fine-grain wrought micr...
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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.
Abstract: Friction stir welding (FSW) has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys. Conventional FSW, however, has not been entirely successful in the joining, processing and manufacturing of different desired materials essential to meet the sophisticated green globe requirements. Through the efforts of improving the process and transferring the existing friction stir knowledge base to other advanced applications, several friction stir based daughter technologies have emerged over the timeline. A few among these technologies are well developed while others are under the process of emergence. Beginning with a broad classification of the scattered frictions stir based technologies into two categories, welding and processing, it appears now time to know, compile and review these to enable their rapid access for reference and academia. In this review article, the friction stir based technologies classified under the category of welding are those applied for joining of materials while the remnant are labeled as friction stir processing (FSP) technologies. This review article presents an overview of four general aspects of both the developed and the developing friction stir based technologies, their associated process parameters, metallurgical features of their products and their feasibility and application to various materials. The lesser known and emerging technologies have been emphasized.
232 citations
TL;DR: In this article, a multilayered stack of an Mg-based WE43 alloy was built using FSAM at two different welding parameters, and the maximum hardness of 115 HV was obtained in as-fabricated state and increased to 135 HV after aging.
Abstract: Structural performance is a key challenge pertinent to additive manufacturing. A majority of the current techniques employed for metallic materials involve liquid–solid transformation and their performance is limited by solidification microstructures. Depending on the type of metallic alloy, this can be a serious impediment to structural properties. In this regard, solid-state additive manufacturing techniques have lagged behind. This study is focused on friction stir additive manufacturing (FSAM) as a potential technique to attain structurally efficient magnesium alloys. In this study, a multilayered stack of an Mg based WE43 alloy was built using FSAM at two different welding parameters. Formation of defects is sensitive to the heat input. In addition, dynamic recrystallization led to finer grain size (2–3 μm). Such fine grain size coupled with desirable precipitate characteristics culminated in superior mechanical properties. Maximum hardness of 115 HV was obtained in as-fabricated state and increased to 135 HV after aging. These levels are similar to Al 2XXX alloys. In fact, in terms of strength, it translates to 400 MPa and 17% ductility and is significantly higher than the base material subjected to aging. Mechanical properties have been correlated with detailed microstructural observations. Texture is discussed for a higher heat input sample using orientation imaging microscopy.
109 citations
01 Apr 2007
TL;DR: The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy.
Abstract: Transactions of The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy, materials engineering, physical, chemical and mechanical metallurgy, welding science and technology, surface engineering and characterisation, materials development, thermodynamics and kinetics, materials modelling and to other allied branches of metallurgy and materials engineering.
98 citations
TL;DR: A comprehensive summary of state-of-the-art in fabricating magnesium-based composites by FSP is provided in this article, where the influence of the secondary phase particles and grain refinement resulted from FSP on the properties of these composites is also discussed.
Abstract: Surface metal matrix composites (MMCs) are a group of modern engineered materials where the surface of the material is modified by dispersing secondary phase in the form of particles or fibers and the core of the material experience no change in chemical composition and structure. The potential applications of the surface MMCs can be found in automotive, aerospace, biomedical and power industries. Recently, friction stir processing (FSP) technique has been gaining wide popularity in producing surface composites in solid state itself. Magnesium and its alloys being difficult to process metals also have been successfully processed by FSP to fabricate surface MMCs. The aim of the present paper is to provide a comprehensive summary of state-of-the-art in fabricating magnesium based composites by FSP. Influence of the secondary phase particles and grain refinement resulted from FSP on the properties of these composites is also discussed
71 citations
20 Jan 2016-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing
TL;DR: In this article, an aluminum matrix composite reinforced with titanium particles was successfully friction deposited, and the composite friction deposits showed well-bonded layers, very fine grain size, and uniformly distributed titanium particles.
Abstract: Friction deposition is one of the promising new techniques for additive manufacturing. In this work, an aluminum matrix composite reinforced with titanium particles was successfully friction deposited. The multi-layer composite friction deposits showed well-bonded layers, very fine grain size, and uniformly distributed titanium particles. While the reinforcement/matrix interfaces showed no reaction products, the layer interfaces showed thin intermetallic bands. These brittle intermetallic bands were found to strongly affect the ductility of the multi-layer composite friction deposits in the build direction. However, the composite friction deposits performed satisfactorily in compression tests as well as in single-layer tensile tests.
37 citations
References
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Book•
01 Jan 2009
TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.
Abstract: Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker, more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of AM applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Authors Ian Gibson, David W. Rosen and Brent Stucker explain these issues, as well as: Providing a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches Discussing the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use components Introducing systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing is the perfect book for researchers, students, practicing engineers, entrepreneurs, and manufacturing industry professionals interested in additive manufacturing.
3,013 citations
"Use of Friction Surfacing for Addit..." refers background in this paper
...Finally, part fabrication with these processes typically takes a very long time as the deposition rates are very low (less than 1 gram=minute) [2]....
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Journal Article•
119 citations
01 Apr 2007
TL;DR: The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy.
Abstract: Transactions of The Indian Institute of Metals is devoted to the publication of selected reviews on contemporary topics and original research articles that contribute to the advancement of ferrous and non-ferrous process metallurgy, materials engineering, physical, chemical and mechanical metallurgy, welding science and technology, surface engineering and characterisation, materials development, thermodynamics and kinetics, materials modelling and to other allied branches of metallurgy and materials engineering.
98 citations
Patent•
04 Oct 2000
TL;DR: In this paper, friction heating and bonding are used to consolidate sequentially applied metals, plastics or composites to previously deposited material so as to form a bulk deposit in a desired shape.
Abstract: Friction heating and bonding are used to consolidate sequentially applied metals, plastics or composites to previously deposited material so as to form a bulk deposit in a desired shape. Monolithic or composite sheets, tapes and filaments can be consolidated using the approach. A system according to the invention includes a source of friction; a mechanism for applying a forging load between a feedstock power supply and a work surface; a work-head, which may have various configurations depending on the geometry of the feedstock to be used; a material feeding system; and a computer-controlled actuation system which controls the placement of material increments added to an object being built. A computer model of the object to be built is used to generate commands to produce the object additively and automatically. The approach provides a solid, freeform fabrication technique that requires no tooling, operates in the solid state, and creates a bond directly at the faying surfaces (i.e., acts only at the location where bonding/consolidation of the material increments is desired).
80 citations
TL;DR: In this paper, the authors describe the events that the matrix and carbides experience as the coating material pass from the coating rod to the substrate, in forming the coating, and the coating is observed to harden automatically within a few seconds of being deposited onto the cold substrate.
Abstract: This paper is concerned with the friction surfacing of high-speed steels, BM2, BT15 and ASP30 onto plain carbon steel plate. The events that the matrix and carbides experience as the coating material pass from the coating rod to the substrate, in forming the coating, is described. The coating is observed to harden automatically within a few seconds of being deposited onto the cold substrate. This autohardening is observed to be an inherent feature of the friction surfacing process and the only post-coating heat treatment required is tempering, as with traditionally hardened high-speed steels. The mechanism of autohardening is discussed in terms of the mechtrode/coating/substrate thermal system.
72 citations
"Use of Friction Surfacing for Addit..." refers background in this paper
..., around 1200 C in the case of alloy 410) [15, 16, 19]....
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...2b, friction surfaced deposits typically show lack of bonding at the deposit edges, due to material roll-over [13, 15]....
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