Open Access Open Access  Restricted Access Subscription or Fee Access

A Review of Recent Developments in Solid State-Based Metal Additive Manufacturing: Friction Stir Additive Technique

Utpal Kant, Sanjay Kumar, Anant Prakash Agrawal, Ankit Sharma

Abstract


In the age of machines, the whole industry needs light-weight and high strength for lighter devices, machines, etc. The core aerospace industry needs lighter materials for satellites and rockets. Friction Stir Additive Technology (FSAT)
represents an innovative approach aimed at leveraging the principles of layered build (AM) layer by layer using solid state (FSW) friction stir welding technology. These represent a particular class of friction-based additive technology (FAT) and can easily be regarded as a significant breakthrough in the field of metal additive manufacturing (MAM). Due to the capabilities of the MAM technology used to create complex parts, they have come to be seen as a favourable option for the aerospace,
automotive, and marine industries. Conversely, melt-based MAM technology has many limitations, primarily due to work hardening and insufficient shear strength issues.


Keywords


Composite Material, Metal Matrix Composite, Friction Stir Additive Manufacturing, Friction Stir Welding, Friction Stir Processing, Reinforcement, Microstructure, Strength.

Full Text:

PDF

References


Manu Srivastavaa, Sandeep Ratheeb, Sachin Maheshwaric , Arshad Noor Siddiqueed, and T. K.

Kundrae, A Review on Recent Progress in Solid State

Friction Based Metal Additive Manufacturing: Friction

Stir Additive Techniques, ISSN: 1040-8436 (Print) 1547-

(Online) Journal homepage:

https://www.tandfonline.com/loi/bsms20.

H. Tinmaz, History of industrial revolutions: from homo

sapiens hunters to bitcoin hunters, in: R.R. Rosa, A.

Alberti, M. Singh (Eds.), Blockchain Technology for

Industry 4.0. Blockchain Technologies, Springer,

Singapore, 2020 https://doi. org/10.1007/978-981-15-

-0_1.

A. Ramanathan, P. K. Krishnan, R.Muraliraja, A review

on the production of metal matrix composites through

stir casting – Furnace design, properties, challenges, and

research opportunities, Journal of Manufacturing

Processes,Volume 42, 2019, Pages 213-245, ISSN 1526-

S. Chainarong, P. Muangjunburee, S. Suthummanon,,

Friction Stir Processing of SSM356 Aluminium Alloy,

Procedia Engineering, Volume 97, 2014, Pages 732-740,

ISSN 1877-7058.

Rosa Miranda, Introduction, Surface Modification by

Solid State Processing, Woodhead Publishing, 2014,

Pages xxiii-xxv, ISBN 9780857094681.

Prince V. Cobbinah, Wallace R. Matizamhuka.

Solid-State Processing Route, Mechanical

Behaviour, and Oxidation Resistance of TiAl Alloys.

Advances in Materials Science and

Engineering 2019, Article ID 4251953.

Sandeep Rathee, Sachin Maheshwari, Arshad Noor

Siddiquee& Manu Srivastava. A Review of Recent

Progress in Solid State Fabrication of Composites

and Functionally Graded Systems Via Friction Stir

Processing, Critical Reviews in Solid State and

Materials Sciences 2018; 43:4, 334-366.

Rajinder Kumar, Liquid state fabrication of metal

matrix composite using stir casting, international

journal of Advanced Research in Science and

Engineering 2017.

Tabish Qamar Hashmi, Liquid State Methods of

Producing Metal Matrix Composites: A Review

Article, IJRMET 2015; ISSN: 2249-5762.

ShigehitoDeki, Sachihiko Iizuka, Asako Horie,

Minoru Mizuhata, and Akihiko Kajinami, Liquid-

Phase Infiltration (LPI) Process for the Fabrication

of Highly Nano-Ordered Materials, Chemistry of

Materials 2004 16 (9), 1747-1750.

Manikanda Prasath. K, Vignesh. S. A Review of

Advanced Casting Techniques. Research J.

Engineering and Tech. 2017; 440-446.

S. Singh, S. Ramakrishna, R. Singh, Material issues

in additive manufacturing: A review, J. Manuf.

Process. 25 (2017) 185–200. [10]

S.A.M. Tofail, E.P. Koumoulos, A. Bandyopadhyay,

S. Bose, L. O’Donoghue, C. Charitidis, Additive

manufacturing: scientific and technological

challenges, market uptake and opportunities, Mater.

Today 21 (2018) 22–37.

D.W. Rosen, Research supporting principles for

design for additive manufacturing, Virtual Phys.

Prototyp. 9 (2014) 225 232.

C. Klahn, B. Leutenecker, M. Meboldt, Design

strategies for the process of additive manufacturing,

Procedia CIRP 36 (2015) 230–235.

M.K. Thompson, G. Moroni, T. Vaneker, G. Fadel,

R.I. Campbell, I. Gibson, A. Bernard, J. Schulz, P.

Graf, B. Ahuja, F. Martina, Design for Additive

Manufacturing: Trends, opportunities,

considerations, and constraints, CIRP Ann. 65

(2016) 737–760.

W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G.

Murch, P. Templesmith, and C. J. Dawes: G.B.

(1991) Patent Application No. 9125978.8.

P.L. Threadgill, A.J. Leonard, H.R. Shercliff, P.J.

Withers, Friction stir welding of aluminium alloys,

Int. Mater. Rev. 54 (2009) 49–93.

A. Barcellona, G. Buffa, L. Fratini, D. Palmeri, On

microstructural phenomena occurring in friction stir

welding of aluminium alloys, J. Mater. Process. 177

(2006) 340–343.

D.M. Rodrigues, C. Leit˜ao, R. Louro, H. Gouveia,

A. Loureiro, High speed friction stir welding of

aluminium alloys, Sci. Technol. Weld Joi 15 (2010)

–681.

S. Jana, Y. Hovanski, G. Grant, Friction stir lap

welding of magnesium alloy to steel: a preliminary

investigation, Metall and Mat Trans A 41 (2010)

–3182.

V. Soundararajan, E. Yarrapareddy, R. Kovacevic,

Investigation of the friction stir lap welding of

aluminum alloys AA5182 and AA6022, J. Mater. Eng.

Perform 16 (2007) 477–484.

Q. Yang, S. Mironov, Y.S. Sato, K. Okamoto, Material

flow during friction stir spot welding, Mater. Sci. Eng., A

(2010) 4389–4398.

H. Papahn, P. Bahemmat, M. Haghpanahi, C. Sommitsch,

Study on governing parameters of thermal history during

underwater friction stir welding, Int. J. Adv. Manuf.

Technol. 78 (2015) 1101–1111.

H.J. Liu, H.J. Zhang, L. Yu, Effect of welding speed on

microstructures and mechanical properties of underwater

friction stir welded 2219 aluminum alloy, Mater. Des. 32

(2011) 1548–1553.

G. Zhang, W. Su, J. Zhang, W. Zhongxin, Friction stir

brazing: a novel process for fabricating Al/steel layered

composite and for dissimilar joining of Al to steel,

Metall. Mat. Trans. A 42 (2011) 2850–2861.

S. Xie, R. Li, T. Yuan, C. Chen, K. Zhou, B. Song, Y.

Shi, Laser cladding assisted by friction stir processing for

preparation of deformed crack-free Ni-Cr-Fe coating

with nanostructure, Opt. Laser Technol. 99 (2018)

–381.

T. Nishihara, Development of friction stir forming,

Mater. Sci. Forum 426–432 (2003) 2971–2978.

M. Aonuma, K. Nakata, Effect of alloying elements on

interface microstructure of Mg–Al–Zn magnesium alloys

and titanium joint by friction stir welding, Mater. Sci.

Eng., B 161 (2009) 46–49.

G. Huang, X. Feng, Y. Shen, Q. Zheng, P. Zhao, Friction

stir brazing of 6061 aluminum alloy and H62 brass:

Evaluation of microstructure, mechanical and fracture

behavior, Mater. Des. 99 (2016) 403–411. [77] H. Peng,

R. Li, T. Yuan, H. Wu, H. Yan, Producing

nanostructured Co–Cr–W alloy surface layer by laser

H. Peng, R. Li, T. Yuan, H. Wu, H. Yan, Producing

nanostructured Co–Cr–W alloy surface layer by laser

cladding and friction stir processing, J. Mater. Res. 30

(2015) 717–726.

A.A. Stelt, T.C. Bor, H.J.M. Geijselaers, R. Akkerman,

A.H. van den Boogaard, Cladding of advanced Al alloys

employing friction stir welding, Key Eng. Mater.

–557 (2013) 1014–1021.

J.O. Milewski, Additive manufacturing metal, the art of

the possible, in: Additive Manufacturing of Metals.

Springer Series in Materials Science, Springer, Cham,

, p. 258, https://doi.org/10.1007/978-3-319-58205-

_2.

A. Ebrahimi, Application of Additive Manufacturing in

Marine Industry, J. Mar. Sci. Eng. 5 (2015) 87–92.

F. Froes, R. Boyer, B. Dutta, 1 - Introduction to

aerospace materials requirements and the role of additive

manufacturing, Editor(s): Francis Froes, in: Additive

Manufacturing for the Aerospace Industry, Elsevier,

Rodney Boyer, 2019, pp. 1–6.

K.V. Wong, A. Hernandez, A Review of additive

manufacturing, Int. Sch Res. Network 2012 (2012) 1–10.

Y. Wang, Y.F. Zhao, Investigation of sintering shrinkage

in binder jetting additive manufacturing process, Proc.

Manuf. 10 (2017) 779–790.

A. du Plessis, S.G. le Roux, G. Booysen, J. Els,

Directionality of cavities and porosity formation in

powder-bed laser additive manufacturing of metal

components investigated using X-ray tomography, 3D

Print Addit Manuf. 3 (2016) 48–55.

H. Gong, K. Rafi, H. Gu, T. Starr, B. Stucker, Analysis

of defect generation in Ti–6Al–4V parts made using

powder bed fusion additive manufacturing processes,

Addit. Manuf. 1–4 (2014) 87–98.

M. Marya, V. Singh, S. Marya, J.Y. Hascoet,

Microstructural development and technical

challenges in laser additive manufacturing: case

study with a 316L industrial part, Metall and Mater

Trans B 46 (2015) 1654–1665.

A. Yadollahi, N. Shamsaei, Additive manufacturing

of fatigue resistant materials: Challenges and

opportunities, Int. J. Fatigue 98 (2017) 14–31.

S. Rathee, M. Srivastava, S. Maheshwari, T.K.

Kundra, A.N. Siddiquee, Friction Based Additive

Manufacturing Technologies: Principles for Building

in solid state, Benifits, limitations and applications,

st Edition, (2018) https://doi.org/

1201/9781351190879. [100] M. Srivastava, S.

Rathee, S.

D. White, Object consolidation employing friction

joining, Patents (2002), US6457629B1.

W.M. Thomas, I.M. Norris, D.G. Staines, & E.R.

Watts, Friction stir welding–process developments

and variant techniques, in The SME Summit

Oconomowoc, Milwaukee, USA (2005) 1-21.

E.D. Herderick, Progress in additive manufacturing,

JOM 67 (2015) 580–581.

Z. Zhang, Z.J. Tan, J.Y. Li, Y.F. Zu, W.W. Liu, J.J.

Sha, Experimental and numerical studies of re-

stirring and re-heating effects on mechanical

properties in friction stir additive manufacturing, Int.

J. Adv. Manuf. Tech. 104 (2019) 767–784.

Z. Zhang, Z.J. Tan, J.Y. Li, Y.F. Zu, J.J. Sha,

Integrated modeling of process-microstructure-

property relation in friction.214, September, 2019




DOI: https://doi.org/10.37628/ijmmp.v8i2.1481

Refbacks

  • There are currently no refbacks.