Friction Stir Processing: An Emerging Surface Engineering Technique

Bajakke, Padmakumar A.; Jambagi, Sudhakar C.; Malik, Vinayak; Deshpande, Amruta

doi:10.1007/978-3-030-43232-4_1

Cited by 10 publications

(6 citation statements)

References 62 publications

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“…Porosity was observed in the coating, which allows the molten salt to penetrate and leads to corrosion. Coating flaws and the impurities on the surface lead to the formation of pitting corrosion. , Sreenivas Rao et al reported a similar observation for plasma-sprayed Cr 2 O 3 –Al 2 O 3 –ZrO 2 multilayer coatings on mild steel. However, depositing dense FA coatings can further improve the corrosion resistance.…”

Section: Resultsmentioning

confidence: 76%

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

2022

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Fly ash (FA), a multicompound mineral, is an industrial waste produced during coal burning in thermal power stations. It has been regarded as the most environmentally hazardous material. Furthermore, handling FA has been a significant challenge for many developing countries. Therefore, researchers have been exhorted to enhance its usage to counter its handling issues. FA is enriched with mullite, silica, and alumina. Having such mineralogy, FA can be envisaged as a promising candidate for combating erosion and corrosion in marine environments. With this motivation, the research aims to deposit as-received FA using the plasma-spraying technique onto a marine-grade steel substrate without additives and assess the performance of such coatings for erosion and corrosion properties. The coating has exhibited more than 100% improvement in microhardness. The erosion resistance was improved by ∼11% compared to that of the uncoated sample, which is attributed to the hardness to elastic modulus ratio ( H / E ) and its unique mineralogy. The minor improvement in erosion resistance was attributed to the coating’s poor fracture toughness. The erosion study shows that slurry concentration and rotational speeds were the most influential parameters. The scar depth was significantly shallower for FA-coated samples. The corrosion resistance has improved only by ∼13.49%, owing to the porous nature of the coating. Therefore, such coatings with appropriate improvements in their properties are expected to assuage both environmental and industrial challenges.

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Section: Resultsmentioning

confidence: 76%

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

2022

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“…The intermixing nature along with other inherent characteristics features led to the development of MMC [18]. Surface/bulk MMC can be fabricated by using FSP either as a primary or secondary process [19]. Zykova et al [20].…”

Section: Introductionmentioning

confidence: 99%

Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

Malik

Bajakke

Saxena

et al. 2022

Mater. Res. Express

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The problems associated with the fabrication of in-situ metal matrix composites (MMC) by conventional methods can be avoided by using microwave sintering and friction stirring in combination. The current study investigates the mechanical and electrical properties of pure aluminum (Al-100 wt.%) and Al-Cu MMC. The results showed that excellent ultimate tensile strength, toughness, and electrical conductivity can be acquired simultaneously. The obtained ultimate tensile strength in the case of Al-100wt.% (184.5 MPa) has improved two-fold than that of a typical commercially pure aluminum AA1016 (90 MPa). Similarly, the electrical conductivity of developed pure aluminum (88.87% IACS) is 1.4 times higher compared to AA1016 alloy (62% IACS). For Al-Cu MMC the copper is added in steps of 5 wt.% (5%, 10%, 15%, and 20%). The maximum ultimate tensile strength (205.2 MPa) and the electrical conductivity (71.53% IACS) obtained for Al-10wt.%Cu are higher compared to the AA1016 alloy. The present investigation suggests a novel processing route and opens up new research avenues in the field of solid-state materials processing.

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“…The aluminum possessing high stacking fault energy has an advantage by treating via FSP. In aluminum, the change in microstructure mainly depends on DRX and FSP being an intense plastic deformation process facilitates in attaining the same (Bajakke et al, 2019;Bajakke et al, 2020a;Ramalingam et al, 2019). In the current industrial scenario, aluminum alloys are considerably replacing steel due to their high strength-toweight ratio and corrosion resilience.…”

Section: Introductionmentioning

confidence: 99%

A review on in-situ aluminum metal matrix composites manufactured via friction stir processing: meeting on-ground industrial applications

Prabhu¹,

Bajakke²,

Malik³

2021

WJE

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Purpose In-situ aluminum metal matrix composites (AMMC) have taken over the use of ex-situ AMMC due to the generation of finer and thermodynamically stable intermetallic compounds. However, conventional processing routes pose inevitable defects like porosity and agglomeration of particles. This paper aims to study current state of progress in in-situ AMMC fabricated by Friction Stir Processing. Design/methodology/approach Friction stir processing (FSP) has successfully evolved to be a favorable in-situ composite manufacturing technique. The dynamics of the process account for a higher plastic strain of 35 and a strain rate of 75 per second. These processing conditions are responsible for grain evolution from rolled grain → dislocation walls and dislocation tangles → subgrains → dislocation multiplication → new grains. Working of matrix and reinforcement under ultra-high strain rate and shorter exposure time to high temperatures produce ultra-fine grains. Do the grain evolution modes include subgrain boundaries → subgrain boundaries and high angle grain boundaries → high angle grain boundaries. Findings Further, the increased strain and strain rate can shave and disrupt the oxide layer on the surface of particles and enhance wettability between the constituents. The frictional heat generated by tool and workpiece interaction is sufficient enough to raise the temperature to facilitate the exothermic reaction between the constituents. The heat released during the exothermic reaction can even raise the temperature and accelerate the reaction kinetics. In addition, heat release may cause local melting of the matrix material which helps to form strong interfacial bonds. Originality/value This article critically reviews the state of the art in the fabrication of in-situ AMMC through FSP. Further, FSP as a primary process and post-processing technique in the synthesis of in-situ AMMC are also dealt with.

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Friction Stir Processing: An Emerging Surface Engineering Technique

Cited by 10 publications

References 62 publications

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

A review on in-situ aluminum metal matrix composites manufactured via friction stir processing: meeting on-ground industrial applications

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