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.
347 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.
179 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.
116 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.
115 citations
TL;DR: In this paper, the authors highlight the working principle and the past research work carried out by the various authors that utilize FSAM as a fabrication process and present the current scenario and future scope of the FSAM process are also discussed in detail in terms of its utilization in various sectors of engineering along with estimated future trends.
Abstract: Friction stir additive manufacturing (FSAM) method is one of the growing techniques of additive manufacturing that utilizes the concept of solid state friction stir processing to develop multilayer components through layer by layer joining. The present work aims to highlight the working principle and the past research work carried out by the various authors that utilize FSAM as a fabrication process. Based on the available experimental data, the summary of additive based friction stir processes, type of machine for fabrication, materials, process parameters taken for the study is also discussed in detail. Mechanical properties such as grain refinement, microhardness variation, and tensile strength are also summarized, in comparison with their base materials. In addition, the current scenario and future scope of the FSAM process are also discussed in detail in terms of its utilization in various sectors of engineering along with estimated future trends.
76 citations
References
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TL;DR: In this paper, the effect of the defocusing amount of both laser beam and powder stream on the forming process is investigated in detail, and it is shown that the forming quality is better when the amount of defocusing is between −0.5mm to 0.5 mm and −3mm to −1 mm.
Abstract: Direct Laser Forming (DLF) is a new layer additive manufacturing technique. It is difficult to control the forming process because many technological parameters interplay. Besides three kinds of laser scanning modes (namely, offset contour line mode, parallel line mode, and the offset contour line combined with parallel line fill mode), the effect of the defocusing amount of both laser beam and powder stream on the forming process is investigated in detail in the article. It is shown that the forming quality is better when the defocusing amount of both laser beam and powder stream are, respectively, between −0.5 mm to 0.5 mm and −3 mm to −1 mm, and at the same time, the self-healing phenomenon (namely, the plane quality of the top surface of part tends to decrease) is firstly found under the open loop condition. Based on the forming mechanisms under different defocusing amount, and the comparative study of three kinds of laser scanning modes, high definition steam turbine blade is fabricated by DLF using ...
39 citations
TL;DR: In this paper, the authors used X-ray fluoroscopic imaging to detect a sharp boundary between the substrate and tool steel coatings and showed that a nominal contact pressure as high as 21.8 MPa was required to obtain an adherent coating.
Abstract: Friction surfacing was carried out with tool steel (AISI 01) and inconel 600 consumables on mild steel 1020 substrate in an argon atmosphere. Inconel bonded strongly with the substrate and there was evidence of interfacial compound formation between the substrate and coating. For tool steel coatings, a sharp boundary between the substrate and coating was observed by scanning electron microscopy. X-ray fluoroscopic imaging also revealed this boundary. Mechanical interlocking between the coating and the substrate appears to be insignificant so adhesion between the coatings and the substrate may be caused by solid-phase bonding. For friction surfacing of both tool steel and inconel, a nominal contact pressure as high as 21.8 MPa was required to obtain an adherent coating of uniform quality. © 1998 Chapman & Hall
39 citations
TL;DR: In this paper, infrared (IR) thermography was used to measure thermal profiles in the coating, consumable rod, and substrate during friction surfacing and a sudden raise followed by a steady state in thermal profile was observed and attributed to viscous heat dissipation during plastic deformation.
Abstract: Infrared (IR) thermography was used to measure thermal profiles in the coating, consumable rod, and substrate during friction surfacing. A sudden raise followed by a steady state in thermal profile was observed and attributed to viscous heat dissipation during plastic deformation. The retreating side of the coating experienced higher temperature compared to the advancing side, indicating that the hot plasticized metal is carried from the advancing side to the retreating side.
36 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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TL;DR: In this paper, the authors developed a new method of friction surfacing repairs to be processed under the melting point of the substrate after the surface grooving of SCC, and demonstrated its applicability in-situ.
Abstract: Some of Japan's ageing operating nuclear power generators are entering their 30th year, which is close to their designed lifespan. With this in mind, JSME (Japan Society of Mechanical Engineer) issued Rules on fitness-for-service for nuclear power plants in May 2000, in which operating plants' maintenance rules were defined and the urgent need for in-situ repair methods on nuclear power plant flaws stated. Because low heat input repairs are necessary for the aged materials of the plants, the authors developed a new method of friction surfacing repairs to be processed under the melting point of the substrate after the surface grooving of SCC, and demonstrated its applicability in-situ.
35 citations
"Use of Friction Surfacing for Addit..." refers background in this paper
...Apart from depositing coatings, the process can be utilized for repair of defective or service-damaged metallic components [18]....
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TL;DR: In this paper, a martensitic stainless steel AISI 410 was friction surfaced over mild steel substrates and its microstructures were characterized using light microscopy, scanning electron microscopy and Xray diffraction.
Abstract: Friction surfacing is a candidate process for depositing corrosion and wear resistant coatings. Being a solid-state process, it offers several advantages over conventional fusion welding based surfacing process. In the current work, martensitic stainless steel AISI 410 was friction surfaced over mild steel substrates. Coating microstructures were characterized using light microscopy, scanning electron microscopy and Xray diffraction. Coatings in as-deposited condition exhibited a fully martensitic microstructure and were found to be quite hard (with an average hardness of 460 HV). Bend and shear tests indicated excellent coating/substrate bonding. Overall, the current work shows that martensitic stainless steel AISI 410 can be satisfactorily friction surfaced on mild steel.
24 citations
"Use of Friction Surfacing for Addit..." refers background in this paper
...2b, friction surfaced deposits typically show lack of bonding at the deposit edges, due to material roll-over [13, 15]....
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