Friction stir processing

About: Friction stir processing is a research topic. Over the lifetime, 2977 publications have been published within this topic receiving 62158 citations.

Assessment of tool wear and mechanical properties of Al 7075 nanocomposite in friction stir processing (FSP)

Abstract: The aim of this study is to investigate the tool wear on friction stir processing of Al7075 base nanocomposite. The silicon carbide nanopowder was used as a reinforcing phase. The effects of input parameters including rotation speed, traverse speed and the pass number on the tool wear, microhardness and the topography were studied through the response surface methodology. Each of the input process parameters was selected in five levels, and other parameters were considered constant. The friction stir tools were examined under a scanning electron microscope, and wear mechanisms were investigated at different conditions. The analysis of variance revealed that quadratic polynomial models are fitting to predict tool wear and microhardness. In addition, the results showed that tool wear also varied between 12 and 116 mm under different parameters. Furthermore, the rotation speed and pass number of 52.9% and 13.1%, respectively, have the greatest impact on tool wear. Traverse speed with more than 55% had the most effect on microhardness comparatively. Also, energy-dispersive spectroscopy analysis showed that with the highest percentage of Fe in rotation speed 900 rpm, traverse speed 50 mm/min and with three passes, the microhardness reached the highest level of 127.24 Vickers.

Effect of Friction Stir Processing on Microstructure and Mechanical Properties of AlSi10Mg Aluminum Alloy Produced by Selective Laser Melting

Abstract: Friction stir processing (FSP) was successfully applied to AlSi10Mg alloy produced by selective laser melting. The microstructure, microhardness, and room-temperature tensile property of the FSPed AlSi10Mg alloy were investigated. The results showed that FSP eliminated the pores of the AlSi10Mg alloy and achieved the microstructural refinement, homogenization, and densification. The grain size was refined from 13.6 μm to 2.3 μm, and relative density increased from 93.3% to 99.6%. An increase in rotation speed led to the enhancement in the density; however, it slightly affected the grain size in this study. The Si particles were homogenously dispersed in the Al matrix, which resulted in uniform distribution of microhardness. FSP led to the increase in the elongation of the AlSi10Mg alloy by 298%, while ultimate tensile strength decreased by only 8%. The Orowan and dislocation strengthening mechanisms were responsible for the loss of strength. FSP has the advantage of acquiring good ductility while maintaining high strength.

Formation of Self-Assembled Monolayer and Characterization of AA7075-T6/B4C Nano-ceramic surface composite using Friction Stir Processing

Abstract: In the present study, Manufacturing of AA7075-T6 and boron carbide nano-ceramic particles using Friction stir processing (FSP) has been done. FSP technique has been widely utilized for surface modification and the formation of composite material. The B4C nanoparticles size(<30nm) as reinforcement were padded in dimension of 2mm width and 1.5mm depth groove of AA7075-T6 plate as a matrix material. The single-pass process executed using a square tool pin with tool rotation and traverse speed of 1000rpm and 40mm/min respectively. This research aims to observe and process Self-Assembled Monolayer (SAM), investigate the effect of the B4C nano-ceramic particles on the AA7075-T6 and its mechanical properties of the nano-ceramic surface composite. Frictional and wear analysis investigations under various physical conditions have highlighted surface durability characteristics of the metal matrix composite of AA7075-T6. Microstructure results along with fractography-image highlight the homogeneous distribution of boron carbide nano-ceramic particle. Tensile test, Microhardness, microstructure, Field Emission Scanning-Electron Microscope (FESEM), and X-Ray Diffraction (XRD) analyzed the fabricated (Al + B4C) nano-ceramic surface composite. The fabricated nano-ceramic surface composite could be utilized in lightweight applications such as aerospace, marine, defence, and automotive industry.

Characterization of Engineered Nickel-Base Alloy Surface Layers Produced by Additive Friction Stir Processing

Abstract: Additive friction stir processing (AFSP) was used as a novel method to create consolidated γ′-strengthened superalloy surface layers on non-age-hardenable Ni-alloy substrates. A Ni–Cr–Mo superalloy (Haynes Alloy 282) was deposited onto Ni–Cr–Fe alloy (INCONEL™ Alloy 600) plate using a cold-wire gas tungsten arc process and subsequently friction stir processed. Alloy 282 was incorporated into the surface and led to increases in near-surface hardness to levels over 275 HV0.3 as-processed. Heat treatment response and precipitate distribution also improved as a result of AFSP. The application of AFSP led to a 2-fold increase in hardness after a direct age heat treatment relative to the as-deposited GTAW weld overlay without AFSP. Enhancement of precipitate formation kinetics was attributed to stored energy from mechanical stirring of the additive Alloy 282 at high temperature. Electron backscatter diffraction and transmission electron microscopy of AFSP regions showed increased dislocation density for low AFSP heat input processing parameters.