A review on friction stir-based channeling

Abstract

Friction stir-based channeling is a solid-state processing encompassing the friction stir channeling (FSC) and its variants. In one manufacturing action, the FSC delivers a subsurface internal closed channel in a monolithic plate with no length limitation. The unique characteristics of theses internally closed channels produced with FSC can fit the demand from several industrial fields, namely lightweight structurally stiffened panels and applications where high power density requires highly efficient thermal management systems, such as power electronics and electric vehicles-based transportation. This first review on the FSC and its variants encompasses a systematic and comprehensive understanding on physical properties, including thermal performance and channel manufacturability applied to different engineering materials. The discussion is emphasized on working principle of channel formation, tool design, influence of process parameters, geometrical characterization, mechanical properties, hardness field and microstructural features correlated with mechanical properties. It can be summarized that novel processing of channels by FSC enhances the thermal performance compared to conventional fabrication techniques. FSC can produce complex path channels with various sizes, shapes and surface finishing. Precise control on process parameters and material flow governs the channel formation that subsequently influences thermal and mechanical performances of the channels. FSC has been applied to different range of thermal management systems and has potential for many demanding existent applications and enabling new high-performance products. From the initial FSC concept based on a shoulder-workpiece clearance, to the most recent solutions, such as the stationary shoulder FSC, and the no-tilt-angle and no-shoulder-workpiece clearance, allowing the manufacturing of large size channels, leaving the processed surface at its original quota and ready to be used. A significant leap is introduced with the Hybrid FSC enabling simultaneous welding and channeling, of similar and dissimilar metal components, and therefore, enhancing design opportunities for even more competitive solutions.

Novel Technique for Design and Manufacture of Alternating Gradient Composite Structure of Aluminum Alloys Using Solid State Additive Manufacturing Technique

“…This way of manufacturing is called beamless additive manufacturing, as the raw materials do not melt during the process [ 11 , 12 ]. Multiple layers of metal sheets or plates are joined together by the frictional heat produced by the contact of raw materials and the rotating tool [ 13 ]. In this technique, heat generated due to friction is much lower than the temperature at which the base metal melts.…”

A Review of Orbital Friction Stir Welding

“…Such material processing can be performed by the conventional FSP method by introducing structural and/or functional particles by different methods, such as upward friction stir processing (UFSP) [92], or even by incorporating distinct features, such as friction stir-based channeling. As reported by the TWI, friction stir-based channeling was revealed to be remarkably promising in orbital applications, such as relatively compact-size heat exchangers for different thermal management tubular systems, for instance, pipe cooling [93]. Likewise, trends in OFSW encompass better weld quality (attributed to enhanced material mixing and increased tool life), the ability to join complex geometries, improved productivity, and process optimization, including tool design and rotational speed, among others.…”

Friction Stir Welding/Processing of Various Metals with Working Tools of Different Materials and Its Peculiarities for Titanium Alloys: A Review

“…Less in demand are friction drilling technology, friction stir additive technology, friction stir internal channel technology, friction stir soldering, etc. [7][8][9][10]. All these technologies are similar to the friction welding technology widely used in industry [11], but differ from it in purpose, plastic flow geometry, applied technological equipment, and tools.…”