Friction Stir Processing Technology: A Review

Abstract

Friction stir processing (FSP), developed based on the basic principles of friction stir welding (FSW), a solid-state joining process originally developed for aluminum alloys, is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components. The FSP causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity of the processed zone. The FSP technique has been successfully used for producing the fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite and intermetallic compound in situ. In this review article, the current state of the understanding and development of FSP is addressed.

Effect of Processing Parameters on Microstructure and Mechanical Properties of an Al-Al11Ce3-Al2O3 In-Situ Composite Produced by Friction Stir Processing

“…The reinforcing phases were identified as Al 11 Ce 3 and d * -Al 2 O 3 . The average size of the Al 11 Ce 3 particles is approximately 1.4 to 3.5 lm, which depends on the processing parameters used.…”

“…The measured density of the composite was 3.26 ± 0.06 g/cm 3 . From microscopic observations, the SZ was found to be free of porosity.…”

“…The theoretical density for a fully reacted composite was calculated to be 3.19 g/cm 3 . The measured density of the composite was 3.26 ± 0.06 g/cm 3 .…”

“…[1] Mishra and Ma have completed a comprehensive literature review on FSW and FSP. [2] In a recent review article, [3] Ma addressed the current state of the understanding and development of FSP. A variety of effective FSP applications have been shown, as follows: (1) homogenizing the microstructure of Al-based nanocomposites, [4,5] (2) producing Al alloys with an ultrafine-grained structure [6][7][8] and Mg alloys, [9] (3) fabricating a fine-grained superplastic microstructure, [10,11] (4) refining the microstructure of cast-aluminum alloys, [12][13][14][15] (5) forming a surface composite on an aluminum substrate, [16] (6) forming an in-situ metal matrix composite, [17][18][19][20] etc.…”

Effect of Friction Stir Processing on (2024-T3) Aluminum Alloy

“…Improvement of the surface properties of the aluminum alloys can be done by a variety of processes like thermo-mechanical treatment (TMT), equal-channel angular processing (ECAP), high pressure torsion (HPT), accumulative roll bonding (ARB), etc., all of which can be used to produce a fine grain size, are complex and time consuming, e.g., during TMT a solution treatment, over-aging, reducing the thickness reducing the thickness of plates, etc. and are involved, with a resultant reduction in the overall economy of the process [3]. In addition, none of these processes are capable of producing localized surface modification.…”