Friction assisted solid state lap seam welding and additive manufacturing method

Kalvala, Prasad Rao; Akram, Javed; Misra, M.

doi:10.1016/j.dt.2015.11.001

Cited by 14 publications

(12 citation statements)

References 13 publications

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“…31 Multiple track seam welding can also be performed by repeating the same steps as in the friction surfacing technique. 104 Additive manufacturing using friction assisted seam welding. Additive manufacturing using FASW involves seam welding of multiple layers using the above principle applying a single track or multitrack.…”

Section: Friction Assisted Seam Weldingmentioning

confidence: 99%

“…Additive manufacturing using FASW involves seam welding of multiple layers using the above principle applying a single track or multitrack. Studies on this 104 technique have been very scant. Seam welding using materials such as Al6061, Ti6Al4V, and stainless steel AISI 304 for both similar and dissimilar combinations has been done for a thickness of 0.5-5 mm (Figure 13).…”

Section: Friction Assisted Seam Weldingmentioning

confidence: 99%

“…3) Bonding at the edges is inadequate 5 104 Friction assisted seam welding Pinless rotating tool is advanced axially on the top of two plates or sheets placed one over the other. Heat generated due to friction deforms the top layer plastically, and as axial force is continued, plastic deformation continues axially till the top surface of the bottom plate, leading to the joining of both layers.…”

Section: Additive Friction Stir Processmentioning

confidence: 99%

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Review on latest trends in friction-based additive manufacturing techniques

Venkit

Selvaraj

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Additive manufacturing comprises layer-by-layer construction of 3D parts using computer controls. This present-day study reveals a list of novel concepts for additive manufacturing, where the addition of material is achieved in solid-state. Materials joined by solid-state techniques exhibits properties beyond those exhibited by material joined by conventional techniques. This has been investigated in both theoretical and experimental manner in length. However, with the development of additive manufacturing techniques, a wide range of possibilities for fabricating complex structures have been identified, which can never be accomplished by conventional techniques. Research on metal-based additive manufacturing has been comparatively less as these products deprive lateral and transverse strength and have issues of anisotropy, making them unfit for structural applications. Moreover, these techniques are not cost-effective. So to overcome these issues, methods incorporating friction into additive manufacturing have been developed. These solid-state techniques use the principle of layer-by-layer deposition. Most of these techniques utilize the principle of selective deposition of materials to form the desired material layer. In this literature review, different advances, approaches, features, and principles of friction-based material joining techniques alongside additive manufacturing are discussed in detail, which recommends new openings for researchers to work in interdisciplinary research to fabricate structures that can exhibit unique properties. This literature portrays an extensive account of the contemporary methods in the fabrication of structures using friction-based additive manufacturing techniques and highlights areas that are worth further research and necessitate a consistent effort on account of the aforementioned disciplines to advance the modernistic technique. Initially, a brief review of different solid-state additive manufacturing techniques is presented, followed by a comprehensive summary of friction stir-based additive manufacturing techniques such as friction assisted seam welding (FASW), additive friction stir (AFS) process, and friction stir additive manufacturing (FSAM) process.

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Section: Friction Assisted Seam Weldingmentioning

confidence: 99%

Section: Friction Assisted Seam Weldingmentioning

confidence: 99%

Section: Additive Friction Stir Processmentioning

confidence: 99%

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Review on latest trends in friction-based additive manufacturing techniques

Venkit

Selvaraj

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…Given that the primary advantage of UAM is solid-state processing, it is meaningful to consider only solidstate techniques for repair of defects in UAM parts. Several other friction-based solid-state additive manufacturing techniques like friction deposition [25][26], friction lap-seam welding [27] and Friction Stir Additive Manufacturing (FSAM) [28][29] have been proposed and demonstrated for various materials. All these methods involve a layer by layer manufacturing or joining of material to near-net shape and have been suggested for making larger size components compared to UAM.…”

Section: Introductionmentioning

confidence: 99%

Monitoring and repair of defects in ultrasonic additive manufacturing

Nadimpalli

Karthik

Janakiram

et al. 2020

Int J Adv Manuf Technol

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“…Given that the primary advantage of UAM is solid-state processing, it is meaningful to consider only solid-state techniques for repair of defects in UAM parts. Several other friction-based solid-state additive manufacturing techniques like friction deposition [119], friction lap-seam welding [120] and Friction Stir Additive Manufacturing (FSAM) [121,122] have been proposed and demonstrated for various materials. All these methods involve a layer-by-layer manufacturing or joining of material to near-net shape and have been suggested for making larger size components compared to UAM.…”

Section: Sensitivity Analysis On the Inversion Scheme Indicates That mentioning

confidence: 99%

Ultrasonic nondestructive evaluation of metal additive manufacturing.

Nadimpalli¹

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Metal Additive Manufacturing (AM) is increasingly being used to make functional components. One of the barriers for AM components to become mainstream is the difficulty to certify them. AM components can have widely different properties based on process parameters. Improving an AM processes requires an understanding of processstructure-property correlations, which can be gathered in-situ and post-process through nondestructive and destructive methods. In this study, two metal AM processes were studied, the first is Ultrasonic Additive Manufacturing (UAM) and the second is Laser Powder Bed Fusion (L-PBF). The typical problems with UAM components are inter-layer and inter-track defects. To improve the UAM process, an in-situ quality evaluation technique was desired. Several NDE techniques were tested in a lab environment before ultrasonic NDE was chosen as a practical, robust, and cost-effective NDE tool. An in-situ monitoring setup was designed and built on an UAM system. NDE results showed interesting features that were simulated through analytic and finite element wave-propagation models. AM layers with defects were characterized as an intact layer and a finite interfacial stiffness spring. The spring stiffness vi coefficient is a quality parameter that was used to characterize AM layers through a modelbased inversion method. In-situ and post-process NDE provided an understanding of defect generation and propagation in UAM. A novel solid-state repair mechanism based on Friction Stir Processing (FSP) was proposed and demonstrated. The quality of L-PBF components depends on several factors including laser power, scan speed, hatch spacing, layer thickness, particle shape/size distribution and other build conditions. Developing process parameters for a new material is an expensive and complex optimization problem. Post-process ultrasonic NDE tests revealed that the model-based insitu quality monitoring developed for UAM is also applicable to L-PBF Additive Manufacturing. A similar NDE setup was designed and installed on an open-architecture L-PBF system. A layer-by-layer bond quality evaluation demonstrates the ability to detect good-quality bonds hidden behind poor-quality regions for Inconel 625 alloy. A costeffective, process parameter development methodology has been proposed and demonstrated. vii TABLE OF CONTENTS

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Friction assisted solid state lap seam welding and additive manufacturing method

Cited by 14 publications

References 13 publications

Review on latest trends in friction-based additive manufacturing techniques

Review on latest trends in friction-based additive manufacturing techniques

Monitoring and repair of defects in ultrasonic additive manufacturing

Ultrasonic nondestructive evaluation of metal additive manufacturing.

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