Friction Surfacing Deposition by Consumable Tools

2021 ◽  
pp. 1-46
Author(s):  
Ebrahim Seidi ◽  
Scott Miller ◽  
Blair Carlson
Keyword(s):  
Energy Requirement ◽  
Scale Up ◽  
Dissimilar Materials ◽  
Process Variations ◽  
Microstructural Characterization ◽  
Solid Substrate ◽  
Tool Geometry ◽  
Material Transfer ◽  
Friction Stir ◽  
Friction Surfacing

Abstract Friction surfacing is a new variation of friction stir processing for surface property modification of metallic substrates. There is an increasing body of literature about friction surfacing by deposition of metal from a consumable tool to a solid substrate. Friction surfacing has many potential applications in joining, coating for corrosion resistance, and repair of degraded components. This paper presents a review of the basic principles, the latest research, and process variations with emphasis on material properties, microstructural characterization, and effects of process parameters such as axial force, rotational speed, travel speed, material transfer rate, energy requirement, and tool geometry. Different friction surfacing processes are reviewed of novel tool/substrate configurations for material deposition for non-coating purposes like keyhole filling and joining dissimilar materials. Possible future topics of study for this area are discussed, which include deeper understanding of material transfer through metallurgy and FEM and scale up of the technique for practical application.

Friction Surfacing Using Consumable Tools: A Review

2019 ◽  
Author(s):  
Ebrahim Seidi ◽  
Scott F. Miller
Keyword(s):  
Welding Process ◽  
Microstructural Characterization ◽  
Travel Speed ◽  
Solid Substrate ◽  
Friction Stir ◽  
Friction Surfacing ◽  
Material Deposition ◽  
Coating Method ◽  
Process Factors ◽  
Tool Types

Abstract The friction surfacing technique is a new variation of friction stir welding process for modification of the surface properties of the substrate. There is a growing body of literature dealing with friction surfacing by consumable tool. This is a metallic deposition technique in which a rotating consumable tool deposits material onto a solid substrate. Friction surfacing has many applications in welding, coating, repair of defective components, hard surfacing and corrosion protection. This process does not generate high temperatures; therefore this technique is a suitable coating method capable of joining low melting point alloys. This review paper studies the basic principles and the use of friction surfacing as well as a survey of the latest researches and applications with emphasis on superficial and microstructural characterization, tensile, bending, effects of the different process factors such as axial force, rotation and travel speed, material deposition rate, energy consumption and different tool types. This review shows there are a few investigations dealing with novel tool/workpiece configurations for adding material for purposes other than coating, such as keyhole filling or dissimilar material joining. Also, the possible future directions for development and application of this technique are presented.

Characterization of Material Transfer in Friction Stir Processing With a Consumable Tool

2018 ◽  
Author(s):  
Scott Miller
Keyword(s):  
Low Temperature ◽  
Friction Stir Processing ◽  
Steel Substrate ◽  
Low Cost ◽  
Material Transfer ◽  
Friction Stir ◽  
Friction Surfacing ◽  
Potential Benefits ◽  
Cost Of Materials ◽  
Mechanical Bonding

This is a study of material transfer from a consumable tool to a substrate. The major advantage of this technique is material adheres by mechanical bonding at relatively low temperature, with potential benefits of high bonding strength, low temperature and thermal effects, high tolerance to contamination, environmentally benign, and low cost of materials, tooling, and process. There is an increasing need for dissimilar material surfacing and coating applications, leading to the study of the friction surfacing process. Friction surfacing experiments were done for depositing different materials to a steel substrate. Subsequent surface roughness and material analysis was done to characterize the nature of material transfer and adhesion to the substrate. The results suggest that friction stir processing by a consumable tool is capable of producing a smooth coating with good metallurgical properties.

Friction stir welding of T-joints in dissimilar materials: Influence of tool geometry and materials properties

2019 ◽  
Vol 6 (10) ◽  
pp. 106528 ◽  
Author(s):  
Neves Manuel ◽  
Claúdio Silva ◽  
José Moreira Domingos da Costa ◽  
Altino Loureiro
Keyword(s):  
Friction Stir Welding ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
T Joints ◽  
Materials Properties ◽  
Friction Stir

scholarly journals Controllability of joint integrity and mechanical properties of friction stir welded 6061-T6 aluminum and AZ31B magnesium alloys based on stationary shoulder

2019 ◽  
Vol 38 (2019) ◽  
pp. 557-566 ◽  
Author(s):  
Baosheng Wu ◽  
Jinglin Liu ◽  
Qi Song ◽  
Zan Lv ◽  
Wei Bai
Keyword(s):  
Copper Alloys ◽  
Dissimilar Materials ◽  
Mg Alloys ◽  
Joint Surface ◽  
Material Transfer ◽  
Friction Stir ◽  
Stationary Shoulder ◽  
Joint Integrity ◽  
Pin Adhesion ◽  
Al Mg Alloys

AbstractIn order to improve joint integrity and reduce the amount of intermetallic compounds (IMCs), 6061-T6 Al and AZ31B Mg alloys were successfully joined by stationary shoulder friction stir welding (SSFSW). The stationary shoulder effectively enhanced the joint surface integrity and reduced the thickness reduction of the Al/Mg joint. The elimination of pin adhesion was beneficial to increasing material transfer and then improving interfacial joining length of Al/Mg joint. Extremely thin IMCs layer could be achieved because of the heat sink induced by the stationary shoulder. The maximum tensile strength of the Al/ Mg joint reached 137 MPa at a welding speed of 60 mm/min, rotating velocity of 1000 rpm and offset to Mg sheet of 0.3 mm, which was 130% higher than that of conventional joint. SSFSW is feasible and has the potential to join dissimilar materials with the formation of IMCs, such as Al/Mg alloys, Al/copper alloys, Al/titanium alloys and so on.

scholarly journals Experimental Analysis and Mathematical Model of FSW Parameter Effects on the Corrosion Rate of Al 6061-T6-Cu C11000 Joints

Crystals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 294
Author(s):  
Félix Alan Montes-González ◽  
Nelly Abigaíl Rodríguez-Rosales ◽  
Juan Carlos Ortiz-Cuellar ◽  
Carlos Rodrigo Muñiz-Valdez ◽  
Josué Gómez-Casas ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Corrosion Rate ◽  
Low Cost ◽  
Weld Zone ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Microstructural Characterization ◽  
Friction Stir ◽  
Al 6061 ◽  
Feasible Option

Friction stir welding is characterized as an ecological and low-cost process in comparison to traditional welding techniques, and due to its application in the solid state, it is a feasible option for joining similar and/or dissimilar materials. The present investigation seeks to determine the effect of friction stir welding’s parameters on the corrosion resistance of an Al 6061-T6–Cu C11000 dissimilar joint, with mathematical analysis to validate the results. After the welding process, the samples were exposed to a NaCl solution in an electrochemical cell to determine the corrosion rate via potentiodynamic tests. Microstructural characterization revealed a laminar structure, composed of aluminum and copper, as well as copper particles and the formation of intermetallic compounds distributed in the weld zone. The potentiodynamic tests showed that the corrosion rate increased with the rotational and traverse speeds. The mathematical model quantifies the relationship between corrosion rate and rotational and traverse speeds.

scholarly journals Material flow in Friction Stir Welding

2008 ◽  
Vol 14 (S3) ◽  
pp. 87-90 ◽  
Author(s):  
C. Leitão ◽  
R.M. Leal ◽  
D.M. Rodrigues ◽  
P. Vilaça ◽  
A. Loureiro
Keyword(s):  
Plastic Deformation ◽  
Friction Stir Welding ◽  
Automotive Industry ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
X Ray ◽  
Friction Stir ◽  
Solid State Joining

Friction stir welding (FSW) is a solid-state joining technique initially developed for aluminium alloys. The heat generated by a rotating tool softens the material in the vicinity of the tool. The material undergoes intense plastic deformation following quite complex paths around the tool, depending on the tool geometry, process parameters and material to be welded. The comprehension of the material flow is essential to prevent voids and other internal defects which may form during welding. Several techniques have been used for tracking material flow during FSW such as metallography, the use of a marker material as a tracer or the flow visualization by FSW of dissimilar materials or even the X-ray and computer tomography. Some of these techniques are useless in the analysis of welds in homogenous materials or welds between materials of the same group. The aim of this investigation is tracking the material flow in FSW between 1mm thick sheets in aluminium alloys AA 5182-H111 and AA 6016-T4, currently used in automotive industry.

Corrosion Behavior and Microstructural Characterization of Friction Stir Welded API X70 Steel

2021 ◽  
Author(s):  
J. M. Giarola ◽  
J. W. Calderón-Hernández ◽  
F. F. Conde ◽  
J. B. Marcomini ◽  
H. G. de Melo ◽  
...  
Keyword(s):  
Corrosion Behavior ◽  
Microstructural Characterization ◽  
Friction Stir

scholarly journals Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1157
Author(s):  
Danka Labus Zlatanovic ◽  
Sebastian Balos ◽  
Jean Pierre Bergmann ◽  
Stefan Rasche ◽  
Milan Pecanac ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Spot Welding ◽  
Minimum Energy ◽  
Tool Geometry ◽  
Friction Stir ◽  
Minimum Energy Consumption ◽  
Punch Test ◽  
Wide Range ◽  
Lap Welding

Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.

Sign in / Sign up

Export Citation Format

Share Document