Review on latest trends in friction-based additive manufacturing techniques

Abstract

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.

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

“…Comparing FSAM to other solid-state techniques, the primary advantages of FSAM are the formation of strong diffused bonds between layers and a greater deposition rate [ 15 ]. In this AM technique, multiple layers of dissimilar or similar materials are joined by stacking the plates one over the other, and the joining of these plates is carried out using the FSLW technique until the required height is obtained ( Figure 1 b) [ 16 ]. FSAM is superior to fusion-based AM techniques since it is accomplished in the solid state without melting the metals, thus preventing any solidification defects in the fabricated components and undesirable phase transition in metallurgy.…”

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

“…As can be seen, an “M” shape behavior is obtained across the workpiece cross section. This shows that at the sides of the workpiece higher stress is obtained in comparison to the center [ 47 , 48 , 49 , 50 ].…”

“…Furthermore, a boundary condition is defined as the clamping of the workpiece. As the process continues, the workpiece tends to have a concave shape, and the clamping force resists against this trend; thus, a high stress is observed at the sides of the workpiece [ 47 , 48 , 49 , 50 ]. Figure 8 indicates the longitudinal stress distribution during the process.…”

A Review of the Metal Additive Manufacturing Processes

“…The joint creation is made possible as a result of the material transfer, heat generation, and material consolidation from the front to the tool's rear parts. In addition to process parameters, the tool geometry during FSAM also partially defines the macroscopic and microscopic aspects of the manufactured parts [71][72][73]. solidation from the front to the tool's rear parts.…”