A Comprehensive Review of Friction Stir Additive Manufacturing (FSAM) of Non-Ferrous Alloys

Abstract

Additive manufacturing is a key component of the fourth industrial revolution (IR4.0) that has received increased attention over the last three decades. Metal additive manufacturing is broadly classified into two types: melting-based additive manufacturing and solid-state additive manufacturing. Friction stir additive manufacturing (FSAM) is a subset of solid-state additive manufacturing that produces big area multi-layered components through plate addition fashion using the friction stir welding (FSW) concept. Because of the solid-state process in nature, the part produced has equiaxed grain structure, which leads to better mechanical properties with less residual stresses and solidification defects when compared to existing melting-based additive manufacturing processes. The current review article intends to highlight the working principle and previous research conducted by various research groups using FSAM as an emerging material synthesizing technique. The summary of affecting process parameters and defects claimed for different research materials is discussed in detail based on open access experimental data. Mechanical properties such as microhardness and tensile strength, as well as microstructural properties such as grain refinement and morphology, are summarized in comparison to the base material. Furthermore, the viability and potential application of FSAM, as well as its current academic research status with technology readiness level and future recommendations are discussed meticulously.

A Framework to Simulate Friction Stir Additive Manufacturing (FSAM) Using the Finite Element Method

“…Thus, a lot of researchers focused on the finite element modeling of this advanced manufacturing processes for magnesium alloys [ 3 , 4 ]. Friction stir additive manufacturing (FSAM) is one the advanced manufacturing processes that have been recently developed by many researchers [ 5 , 6 ]. The process requires a complicated thermomechanical and friction behavior.…”

“…The process requires a complicated thermomechanical and friction behavior. Accordingly, the experimental and numerical investigation of the process is still ongoing by many scholars [ 5 , 6 ].…”

Advanced Analytical Methods of the Analysis of Friction Stir Welding Process (FSW) of Aluminum Sheets Used in the Automotive Industry

“…In addition, the force applied to the rotating tool during the process itself must be appropriately selected, as the pressure generated at the tool’s thrust surface and under the pin tip determines the heat generation during the process [ 10 ]. The rotational speed and feed rate must also be selected appropriately in order to obtain efficient joints [ 12 ]. In friction stir welding (FSW), a rotating tool with a given profile moves forward along the weld line [ 12 , 13 ].…”

“…The rotational speed and feed rate must also be selected appropriately in order to obtain efficient joints [ 12 ]. In friction stir welding (FSW), a rotating tool with a given profile moves forward along the weld line [ 12 , 13 ]. Frictional contact between the FSW tool and the workpiece and plastic dissipation are responsible for heat generation and material softening [ 14 , 15 ].…”

Computational Modelling and Comparative Analysis of Friction Stir Welding and Stationary Shoulder Friction Stir Welding on AA6061

“…FSW, a potential solid-state joining method, has gained commercial momentum in several fields, including rail, automotive, marine, and aerospace [2]. The friction-based solid-state processes have significantly contributed to the advancements in Industry 4.0 and advanced manufacturing techniques [3]. The several benefits of FSW are made possible by using aluminium alloys throughout a broad temperature range, from cryogenic to moderately higher temperatures [4].…”