Friction Stir Welding and Processing E-Book
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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
A single source of information on the fundamental concepts and latest research applications of friction stir welding and processing Friction Stir Welding and Processing: Fundamentals to Advancements provides concise yet comprehensive coverage of the field of friction stir welding, with an eye toward future research directions and applications. Throughout the book, case studies provide real-world context and highlight applications for various engineering sectors. With contributions from an array of leaders in the field, Friction Stir Welding and Processing provides readers with a single source of information on all aspects of FSW and FSP. After explaining the fundamentals of friction stir welding (FSW) and its variants, the book discusses composite fabrication techniques using friction stir processing (FSP). Different types of friction techniques are covered, as is the equipment used. Detailed characterization of samples and composites are included. Additional topics discussed include the impact of FSW on the economics of production, methods for coupling FSW/FSP with additive manufacturing, composite fabrication, and process-property relationships. * Master the basic concepts of friction stir welding and its variants * Discover the role of FSW in developing hybrid manufacturing techniques * Follow case studies that connect theoretical concepts to real-world experimental results * Learn from contributions from an array of global thought leaders in the field This is a valuable compendium on the topic for engineers and designers who utilize welding and advanced manufacturing across industries, as well as graduate students and post-graduate researchers who are exploring new friction stir welding applications.
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Veröffentlichungsjahr: 2024
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Table of Contents
Cover
Table of Contents
Title Page
Copyright
About the Editors
List of Contributors
Preface
Acknowledgments
List of Figures
List of Tables
1 Friction Stir Welding: An Overview
1.1 Introduction
1.2 FSW Working Principle
1.3 Weld Zones
1.4 Variants of FSW
1.5 Defects
1.6 Advantages and Limitations of FSW
1.7 Conclusion and Future Prospectus
Acknowledgments
References
2 Friction Stir Welding and Single-Point Incremental Forming:
State-of-the-Art
2.1 Introduction
2.2 Friction Stir Welding (FSW)
2.3 Single-Point Incremental Forming (SPIF)
2.4 FSW and SPIF
2.5 Summary and Outlook
References
3 Friction Stir Brazing and Friction Stir Vibration Brazing
3.1 Introduction to FSB
3.2 Variants of FSB
3.3 Two Case studies
3.4 Application of FSB and Its Variants in Industry
3.5 Summary and Future Directions
References
4 Fundamentals of Friction Stir Processing
4.1 Friction Stir Processing (FSP): Background
4.2 Working Principle of FSP
4.3 Comparison with Other Severe Plastic Deformation (SPD) Techniques
4.4 Process Variables
4.5 Mechanisms of Microstructural Evolution During FSP
4.6 Critical Issues in FSP
4.7 Future Scope
References
5 Role of FSP in Surface Engineering
5.1 Introduction
5.2 Role of Surface Modification Techniques
5.3 Thermal Spray Technique
5.4 FSP – Solid-State Coating Process
5.5 Process Parameters of FSP: Surface Engineering
5.6 Inappropriate Characteristics of Surface Modification
5.7 Summary
References
6 Surface Composite Fabrication Using FSP
6.1 Introduction
6.2 Reinforcement Incorporation Approaches
6.3 Effect of Process Parameters
6.4 Microstructural Evolution and Mechanical Properties
6.5 Strengthening Mechanisms
6.6 Defects
6.7 Summary and Future Directions
References
7 Friction Stir Welding of Dissimilar Metals
7.1 Introduction
7.2 Application Areas of Dissimilar Material Joining
7.3 Issues for Dissimilar Material Joining
7.4 FSW of Dissimilar Materials
7.5 Recent Developments in Tool Design and Tool Materials
7.6 Parameter Optimization
7.7 Common Defects that Occur in FSW of Dissimilar Metal Joining
7.8 Future Recommendations for Dissimilar Metal Joining
Acknowledgments
References
8 Friction Stir Welding of Aluminum and Its Alloy
8.1 Introduction
8.2 Fundamentals of FSW
8.3 FSW of Aluminum and Its Alloy
8.4 Influences of Process Parameters
8.5 Testing and Characterization of FSW of Al and Its Alloy
8.6 Additive Mixed Friction Stir Process of Al and Its Alloy
8.7 Applications
8.8 Conclusions
References
9 Mechanical Characterization of FSWed Joints of Dissimilar Aluminum Alloys of AA7050 and AA6082
9.1 Introduction
9.2 Materials and Methods
9.3 Results and Discussion
References
10 Sample Preparation and Microstructural Characterization of Friction Stir Processed Surface Composites
10.1 Introduction
10.2 Sample Preparation for Microscopic Analysis of Metals, Alloys, and Composites
10.3 Etching
10.4 Microstructural Evolution
Acknowledgment
References
11 Microstructural Characterization and Mechanical Testing of FSWed/FSPed Samples
11.1 Introduction
11.2 Microstructural Characterization
11.3 Mechanical Testing
11.4 Conclusions
References
12 Comparative Analysis of Microstructural and Mechanical Characteristics of Reinforced FSW Welds
12.1 Introduction
12.2 Friction Stir Welding (FSW)
12.3 Reinforcing Materials-Based Fabrication of FSW Welds
12.4 Joinability of Reinforced FSW Welds
12.5 Metallurgical Characteristics of FSW Reinforced Welds
12.6 Mechanical Behavior of Reinforced FSW Welds
12.7 Conclusions
12.8 Future Challenges
References
13 Summary of Efforts in Manufacturing of Sandwich Sheets by Various Joining Methods Including Solid-State Joining Method
13.1 Introduction
13.2 Sandwich Sheets
13.3 Classification of Sandwich Sheet Structures
13.4 Applications
13.5 Fabrication Methods
13.6 Summary
References
14 Defects in Friction Stir Welding and its Variant Processes
14.1 Introduction
14.2 General Defects in FSW
14.3 Characteristic Defects in Friction Stir Butt and Lap Joints
14.4 Distinctive Defects in Major Friction Stir Variants
14.5 Solutions to Avoid Defects in Friction Stir-Based Processes
14.6 Summary and Concluding Remarks
Acknowledgment
References
15 Nondestructive Ultrasonic Inspections, Evaluations, and Monitoring in FSW/FSP
15.1 Introduction
15.2 Ultrasonic Wave Behaviors in FSWed/FSPed Samples
15.3 Common Ultrasonic Inspection and Evaluation Methods for FSWed/FSPed Samples
15.4 Case Studies on Recent Novel Ultrasound Evaluation and Monitoring in FSW/FSP
15.5 Roles and Potentials of Ultrasound in Future FSW/FSP
15.6 Conclusion
Acknowledgment
References
16 Applications of Friction Stir Welding
16.1 Introduction
16.2 Application of FSW on Different Materials
16.3 Industrial Applications of FSW
16.4 Conclusion
References
17 Equipment Used During FSP
17.1 Introduction
17.2 FSP Experimental Setup
17.3 Microstructural Characterization
17.4 Mechanical Behavior of Composites Based on Various Tool Shapes
17.5 Mechanical behavior of Composites Based on Various Process Parameters
17.6 Conclusion
References
18 Analysis of Friction Stir Welding Tool Using Various Threaded Pin Profiles: A Case Study
18.1 Introduction
18.2 Geometry Considered
18.3 Results and Discussions – Analysis in ANSYS
18.4 Conclusion
Acknowledgement
References
19 Static Structural and Thermal Analysis of Honeycomb Structure Fabricated by Friction Stir Processing Route: A Case Study
19.1 Introduction
19.2 Modeling Details
19.3 Result and Analysis
19.4 Scope of the Case Study
19.5 Conclusion
Acknowledgement
References
20 Friction Stir-Based Additive Manufacturing
20.1 Additive Manufacturing: An Introduction
20.2 Solid-State AM Processes
20.3 Case Studies of FSAM on Different Materials
20.4 Advantages of FSAM Over Other AM Techniques
20.5 Advancements
20.6 Limitations
20.7 Conclusions and Future prospectives
References
Index
End User License Agreement
List of Tables
Chapter 5
Table 5.1 Macroscopic view of all defects produces during FSP.
Chapter 6
Table 6.1 Defects observed in the surface composites fabricated via FSP.
Chapter 8
Table 8.1 FSW process parameters.
Chapter 9
Table 9.1 Mechanical characteristics of AA7050 and AA6082.
Table 9.2 Chemical composition of Al-alloys.
Table 9.3 Processing parameter for FSW.
Table 9.4 Tensile properties of the welded joint.
Chapter 10
Table 10.1 Microstructural characteristics in different zones after FSP.
Chapter 12
Table 12.1 Effect of additional reinforcement on the effectiveness of FSW w...
Chapter 14
Table 14.1 External defects.
Table 14.2 Internal defects.
Table 14.3 Characteristic difference in butt and lap welds.
Chapter 19
Table 19.1 Statistics of the HCS structure.
Table 19.2 Input parameter for stress and strain.
Table 19.3 Stress analysis results.
Table 19.4 Strain analysis results.
Table 19.5 Input for thermal analysis.
Table 19.6 Heat flux result.
Chapter 20
Table 20.1 Comparison of two solid-state AM process, USAM and FSAM [22].
Table 20.2 Summary of mechanical properties of different alloys fabricated ...
List of Illustrations
Chapter 1
Figure 1.1 Friction stir welding setup.
Figure 1.2 (a) Schematic of FSW process. AS: Advancing side, RS: Retreat...
Figure 1.3 Various welding zones associated with FSW.
Figure 1.4 Different variants of FSW.
Figure 1.5 Schematics diagram of FSSW: (a) Tool rotation, (b) Plunge, (c) D...
Figure 1.6 Stationary shoulder FSW.
Figure 1.7 Illustration of FSR for two dissimilar metals: (a) holding of th...
Figure 1.8 Schematic view of FricRiveting process.
Figure 1.9 Friction stir blind riveting.
Figure 1.10 Friction stir scribe: (a) Tool, (b) process.
Figure 1.11 Friction surfacing: (a) the end of the consumable tool, (b) the...
Figure 1.12 Schematic arrangement of FSP.
Chapter 2
Figure 2.1 Third body area in friction stir welding using (a) a nonconsumab...
Figure 2.2 The FSW process (a) as a schematic and (b) at various phases.
Figure 2.3 Cause–effect diagram.
Figure 2.4 Single-point incremental sheet forming (SPIF).
Figure 2.5 Two-point incremental sheet forming (TPIF).
Figure 2.6 Kinematic incremental sheet forming using two forming tools.
Figure 2.7 Schematic depiction of the SPIF process.
Chapter 3
Figure 3.1 Detailed view of the machine used for friction stir vibration br...
Figure 3.2 A comparison of interface generation during (a) FSB and (b) FSVB...
Figure 3.3 (a) Temperature variation of joint samples for FSB and FSVB proc...
Figure 3.4 A comparison of microstructure evolution of brazing area fabrica...
Figure 3.5 The distribution of SiO
2
nanoparticles in the joint area made by...
Figure 3.6 Hardness variation for brazing samples produced by various joini...
Figure 3.7 Fracture surface analysis of the brazing area under different ma...
Figure 3.8 A comparison of microstructure evolution in the brazing area und...
Figure 3.9 A SEM image of reinforcing distribution in the brazed area under...
Figure 3.10 TEM image of SiC distribution in the brazed samples under vario...
Figure 3.11 (a) Variation in IMC thickness for top and bottom layer of braz...
Chapter 4
Figure 4.1 List of attributes and the potentiality of the FSP as a diversif...
Figure 4.2 The process illustration of FSP.
Figure 4.3 Optical micrograph of FSPed sample (a) at 720 rpm 85 mm/min, (b)...
Figure 4.4 Effect of processing parameters on shapes of NZ in FSP of cast A...
Figure 4.5 Classification of FSP process variables.
Figure 4.6 Basic tool geometry along with different types of pin profile an...
Figure 4.7 Tool travel patterns for FSP: (a) linear and curved single passe...
Figure 4.8 Cross-sectional view of the specimens with various OR: (a) singl...
Figure 4.9 Schematic illustration of cooling-assisted FSP.
Figure 4.10 Schematic of various stages of dynamic recrystallization mechan...
Chapter 5
Figure 5.1 Surface modification technique is a sub-domain of surface engine...
Figure 5.2 Surface modification techniques are categorized [8].
Figure 5.3 Basic mechanism of the thermal spraying coating process.
Figure 5.4 Schematic diagram of FSP along with the pin-less tool.
Figure 5.5 Microscopic image of wear track.
Figure 5.6 (a) Coating peel-off due to thermal stress during cyclic oxidati...
Chapter 6
Figure 6.1 Schematic illustration of FSP.
Figure 6.2 Conventional reinforcement filling methods for the surface compo...
Figure 6.3 Schematic representation of (a) reinforcement filling through dr...
Figure 6.4 Pictorial representation of pasting reinforcement layer followed...
Figure 6.5 OM micrographs from the SZ of the FSPed AZ31 (a and b) and the F...
Figure 6.6 EBSD images (IPF + grain boundary map) of the Al–TiC composite s...
Figure 6.7 Grain size and cluster size variation with the number of FSP pas...
Figure 6.8 Optical micrograph displaying fine and equiaxed grains in FSP of...
Figure 6.9 Optical micrograph of FS-processed surface composites (a) SiC/A3...
Figure 6.10 Hardness variation with varying volume fraction of SiC in SiC/5...
Figure 6.11 SEM image of the stir zone with groove depth (a,d) 1 mm, (b,e) ...
Figure 6.12 Schematic grain growth restraining by reinforcement particles [...
Figure 6.13 TEM images of (a) MWCNT reinforced in AA5059 alloy after two pa...
Figure 6.14 Microhardness profiles of AA6061-Gr-TiB2 nanocomposites [73].
Chapter 7
Figure 7.1 Distribution of material of total vehicle curb-weight in kilogra...
Figure 7.2 Use of tailor-welded blanks in automobile.
Figure 7.3 Year-wise progression of FSW of dissimilar metal joining.
Figure 7.4 Year-wise progression of FSW of dissimilar aluminum alloy joinin...
Figure 7.5 Complex intercalated material flow pattern in the WZ for FSW of ...
Figure 7.6 Hardness profiles in as-welded and PWHT condition: (a) O joints ...
Figure 7.7 Year-wise progress of FSW of Al–Cu system.
Figure 7.8 Microstructure of Al–Cu FSW system (a) TMAZ and WZ region, (b) T...
Figure 7.9 Year-wise progress of FSW of Al–Ti.
Figure 7.10 Commonly utilized Al–steel joint hybrid structures in various s...
Figure 7.11 Year-wise progression of FSW of aluminum-to-steel material join...
Figure 7.12 Microstructure of FSW of Al–steel joints, (a) complex WZ, (b) A...
Chapter 8
Figure 8.1 Image of the FSW in schematic form.
Figure 8.2 High-strength aluminum plates [Automotives].
Figure 8.3 FSW tools pin profiles. (a) Straight, (b) Tapered, (c) Threaded,...
Figure 8.4 Various zone-optical microscopes.
Chapter 9
Figure 9.1 Experimental setup and FSP tool specification.
Figure 9.2 (a) Stress–strain curve of the FSWed joints of AA6082 and AA7050...
Figure 9.3 Variation of microhardness of the FSWed joints with different RT...
Figure 9.4 Optical microstructure of the welded joint at SZ: (a) welded reg...
Figure 9.5 SEM images of tensile fractured specimen, (a) Specimen 1, (b) Sp...
Chapter 10
Figure 10.1 Direction of sample cutting for microstructural study [23] Rath...
Figure 10.2 Typical belt grinder.
Figure 10.3 (a) Typical arrangement for hot mounting, (b) items for cold mo...
Figure 10.4 (a) Automatic polishing machine; (b) manual disc polishing mach...
Figure 10.5 (a) Polishing of specimen at first paper; (b) polishing of spec...
Figure 10.6 Optical microscope and related parts.
Figure 10.7 Micrograph showing cross-sectional view of AA6063/SiC surface c...
Figure 10.8 Micrographic image of AA6063/SiC surface composite captured via...
Figure 10.9 Various FSPed zones obtained after FSW [8].
Figure 10.10 Microstructural images of Cu/SiC surface composite: (a) BM; (b...
Figure 10.11 Microstructural images captured using SEM: (a) distribution of...
Figure 10.12 Typical SEM and sample holders.
Chapter 11
Figure 11.1 Illustration of basic FSW process.
Figure 11.2 Surface composite fabrication via FSP utilizing the zig-zag hol...
Figure 11.3 Microstructural zones and terminology of friction stir welding....
Figure 11.4 Microstructure images of friction stir welded zones.
Figure 11.5 Spectrum obtained by XRD analysis of SZ 32.
Figure 11.6 FESEM examination of steel/SiC base composite fabricated via FS...
Figure 11.7 EBSD maps for grain boundaries and interfaces for (a) BM, (b) H...
Figure 11.8 Microhardness values enhancement after FSP.
Chapter 12
Figure 12.1 FSW process.
Figure 12.2 Three different types of reinforcement: (a) continuous fibers (...
Figure 12.3 Reservoirs made on BM, interface for the addition of RPs, inclu...
Figure 12.4 Macrostructure of FSW-based AA6082-T6/SiC, O/TiO
2
weld.
Figure 12.5 (a) AA7075-O/SiC. (b) AA6061-T6/AA2024-T351/SiC. and (c...
Figure 12.6 NZ shapes: (a) basin. (b) elliptical.
Figure 12.7 Traverse velocities 16, 20 mm/min for FSW passes-based FSW weld...
Figure 12.8 Heat index, HI, the average grain size in SZ (
ω
2
/V).
Figure 12.9 Effect of the insertion of RPs: (a) pure Cu with SiC. and (...
Figure 12.10 EBSD grain boundary maps, (a) BM, NZ, (b) FSW, and (c) UFSPW, ...
Figure 12.11 At TS of 16 mm/min, FE-SEM pictures together with an EDS exami...
Figure 12.12 (a) TEM pictures.(b) SEM micrographs demonstrating the imp...
Figure 12.13 SEM pictures from SZ center for reinforced FSWed welds (a, b) ...
Figure 12.14 FE-SEM images at interface Al–Fe for welds produced at 16 mm/m...
Figure 12.15 (a) Cu/SiC microhardness profile. (b) microhardness profil...
Figure 12.16 (a, b) FSW process parameters (TRS, TS) and SiC reinforcement ...
Figure 12.17 Fracture locations in MMR-based FSW welds, (a) NZ. (b) AS ...
Figure 12.18 Fractured surfaces of reinforced FSW welds: (a) cleavage (Quas...
Chapter 13
Figure 13.1 Nanjing Foshou lake building with GFPW panels as floor panels d...
Figure 13.2 Stress–strain plot of metal–polymer–metal sandwich sheet struct...
Figure 13.3 Morphology of AFS [(a) macrograph, (b) region of importance]....
Figure 13.4 Grain size measurement of sandwich sheet and bimetallic sheets ...
Figure 13.5 Schematic of ARB process.
Chapter 14
Figure 14.1 Weld photographs showing (a) flash and surface galling, (b) sur...
Figure 14.2 Weld microstructures showing (a) tunnel defect, (b) wormhole, (...
Figure 14.3 Microstructures of weld cross-sections showing LOP and kissing ...
Figure 14.4 Hook defects observed in a lap weld cross sections: (a) overall...
Figure 14.5 A photograph depicting the entry and exit defects in a typical ...
Figure 14.6 Photograph showing the top-view of the weld made from counter-r...
Figure 14.7 Cross section of FSpW joint indicating (a) hooking flaw, partia...
Figure 14.8 Schematic showing the emergence of complex microstructure in FS...
Figure 14.9 FSAM macrostructure with hooking and kissing bond defects captu...
Chapter 15
Figure 15.1 (a) Bistatic time-of-flight measurement. (b) Monostatic time-of...
Figure 15.2 (a) Refraction in a medium with higher sound velocity. (b) Refr...
Figure 15.3 (a) Scattering effect. (b) Dispersion effect.
Figure 15.4 (a) Acoustic wave behavior with a defect with a much larger siz...
Figure 15.5 (a) Void fraction-dependent effective wavelength. (b) Void frac...
Figure 15.6 (a) Attenuation effects in an isotropic microstructure metal. (...
Figure 15.7 (a) Residual stress-dependent effective bulk modulus. (b) Resid...
Figure 15.8 (a) Acoustic inspection at a location without defect (upper) an...
Figure 15.9 (a) Photoacoustic emission. (b) Laser vibration meter.
Figure 15.10 (a) Illustration of typical ultrasonic phased array inspection...
Figure 15.11 (a) Monostatic immersion ultrasonic scan. (b) Bistatic immersi...
Figure 15.12 (a) Wave oscillation is independent with the rotation angle of...
Figure 15.13 (a) Ultrasonic sensors array monitoring in FSW. (b) Top view o...
Figure 15.14 (a) Air coupled monostatic ultrasonic monitoring in FSW/FSP by...
Figure 15.15 (a) Dissimilar copper and steel FSW workpiece. (b) Ultrasonic ...
Figure 15.16 Dissimilar copper and AZ31 FSW workpiece and ultrasonic scanne...
Figure 15.17 (a) Aluminum alloy FSP workpiece. (b) Ultrasonic scanned elast...
Figure 15.18 (a) Residual stress-dependent ultrasonic wave propagation beha...
Figure 15.19 (a) Illustration of the ultrasonic time-of-flight measurement ...
Chapter 16
Figure 16.1 Classification of friction stirring techniques.
Figure 16.2 Schematic representation of FSW method.
Figure 16.3 Longitudinal residual stress distributions measured across the ...
Figure 16.4 Evolution of local strain of the stir zone on the (a) front sid...
Figure 16.5 Macrographs of butt welds: (a) TIMET-54M; (b) ATI-425; (c) Ti-6...
Figure 16.6 Line scan residual stress data at a depth of 1.4 mm from the to...
Figure 16.7 Examples of the industrial application of friction stir welding...
Chapter 17
Figure 17.1 Schematic representation of FSP process.
Figure 17.2 Different zones of friction stir processed sample.
Figure 17.3 Conventional FSP machine.
Figure 17.4 Pictorial representation of 4-axis friction stir welding machin...
Figure 17.5 Different shoulder profiles.
Figure 17.6 Various tool geometry employed like cylindrical pin and polygon...
Figure 17.7 Optimal microstructure of FSPed structural steel by different p...
Figure 17.8 Different pin profiles of Al
−
Cu and their micro and macro...
Figure 17.9 Macrostructure interpretations of the A6061 aluminum alloy deve...
Figure 17.10 Microstructure analysis in AZ91/Al
2
O
3
composite fabricated at ...
Figure 17.11 Optical micrographs showing the microstructure using standard ...
Figure 17.12 Influence of square pin profile tool with different rotational...
Figure 17.13 Microhardness variation values of ST14 structured steel for di...
Figure 17.14 Image displaying the results of friction stir processed stainl...
Figure 17.15 Hardness profile of specimens at rotational speed of 1250 rpm:...
Chapter 18
Figure 18.1 Schematic representation of the FSW process.
Figure 18.2 Parameters affecting the performance and weld quality of the FS...
Figure 18.3 A labeled FSW tool.
Figure 18.4 Models for FSW tools with different pin profiles: (a) cylindric...
Figure 18.5 Stress distribution of FSW tool with cylindrical pin.
Figure 18.6 Stress distribution of FSW tool with conical pin.
Figure 18.7 Stress distribution of FSW tool with cuboidal pin.
Figure 18.8 Variation of stress distribution with temperature in cylindrica...
Figure 18.9 Variation of stress distribution with temperature in cubical pi...
Figure 18.10 Stress distribution varies with temperature in cuboidal pin pr...
Figure 18.11 Comparative stress distribution variation with temperature in ...
Chapter 19
Figure 19.1 Honeycomb structure.
Figure 19.2 Hexagonal cell extrude.
Figure 19.3 Sandwich honeycomb structure.
Figure 19.4 Fixed beam.
Figure 19.5 Equivalent stress distribution for the HCS model developed.
Figure 19.6 Equivalent strain analysis.
Figure 19.7 Thermal strain analysis.
Figure 19.8 Total heat flux analysis.
Chapter 20
Figure 20.1 Various AM processes categorized based on FBAM.
Figure 20.2 Schematic representation of FSAM process.
Figure 20.3 Schematic showing microstructure evolution in each heat-affecte...
Figure 20.4 (a) Cross-section overview of the Al alloy composite fabricated...
Figure 20.5 (a) Schematic of FSAM process of Fe and Cu sheets. (b) EBSD-IPF...
Guide
Cover
Table of Contents
Title Page
Copyright
About the Editors
List of Contributors
Preface
Acknowledgments
List of Figures
List of Tables
Begin Reading
Index
End User License Agreement
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Friction Stir Welding and Processing
Fundamentals to Advancements
Edited By
Dr. Sandeep Rathee
Department of Mechanical Engineering,
National Institute of Technology Srinagar
Jammu and Kashmir, India-190006
Dr. Manu Srivastava
Department of Mechanical Engineering,
PDPM Indian Institute of Information Technology,
Design and Manufacturing Jabalpur,
Madhya Pradesh, India-482005
Dr. J. Paulo Davim
Department of Mechanical Engineering,
University of Aveiro,
Campus Santiago,
3810-193 Aveiro, Portugal
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Library of Congress Cataloging-in-Publication Data:
Names: Rathee, Sandeep, editor. | Srivastava, Manu, editor. | Davim, J. Paulo, editor. | John Wiley & Sons, publisher.
Title: Friction stir welding and processing: fundamentals to advancements / edited by Dr. Sandeep Rathee, Dr. Manu Srivastava, Dr. J. Paulo Davim.
Description: Hoboken, New Jersey : Wiley, [2024] | Includes index.
Identifiers: LCCN 2023049870 (print) | LCCN 2023049871 (ebook) | ISBN 9781394169436 (cloth) |
ISBN 9781394169450 (adobe pdf) | ISBN 9781394169443 (epub)
Subjects: LCSH: Friction stir welding.
Classification: LCC TS228.9. F758 2024 (print) | LCC TS228.9 (ebook) | DDC 671.5/2—dc23/eng/20231205
LC record available at https://lccn.loc.gov/2023049870
LC ebook record available at https://lccn.loc.gov/2023049871
Cover Design: WileyCover Image: © NASA/MSFC/D. Stoffer (public domain)
About the Editors
Dr. Sandeep Rathee is currently serving the Department of Mechanical Engineering, National Institute of Technology Srinagar, Jammu & Kashmir, India, as an Assistant Professor. His previous assignment was as a Post-Doctoral Fellow at Indian Institute of Technology Delhi (IIT Delhi). He is the recipient of the prestigious National Post-Doctoral Fellowship by SERB (Govt. of India). He was awarded PhD degree from Faculty of Technology, University of Delhi. His field of research mainly includes friction stir welding/processing, advanced materials, composites, additive manufacturing, advanced manufacturing processes, and characterization. He has authored over 60 publications in various international journals of repute and refereed international conferences. He has been awarded 10 industrial design patents and 1 copyright. He has authored/edited seven books in the field of advanced manufacturing. He is working as an editor-in-chief of a book series titled “Advanced Manufacturing of Materials” with CRC Press, Taylor & Francis group. He has also worked as managing guest editor for a special issue of a Scopus Indexed Elsevier journal. He is the editor of International Journal of Experimental Design & Process Optimization, Inderscience Publishers. He is associated with several reputed journals in the capacity of editorial member. Additionally, he is serving as a reviewer in more than 30 Journals. He has completed/is handling externally funded projects of more than 07 Million INR in the field of additive manufacturing and friction stir welding. He has supervised/is supervising 4 PhD scholars, 2 MTech, and 20 BTech students. His works have been cited more than 1600 times (as per google scholar).
He has a total teaching and research experience of more than ten years. He has delivered invited lectures, chaired scientific sessions in several national and international conferences, STTPs, and QIP programs. He is a life member of the Additive Manufacturing Society of India (AMSI), and Vignana Bharti (VIBHA).
Orcid id:https://orcid.org/0000-0003-4633-7242
Dr. Manu Srivastava is presently serving PDPM Indian Institute of Information Technology, Design and Manufacturing Jabalpur, India, in the Department of Mechanical Engineering. Her previous assignment was as a Prof. & Head, Department of Mechanical Engineering and Director Research, Faculty of Engineering and Technology, MRIIRS, Faridabad, India. She has completed her PhD in the field of additive manufacturing from Faculty of Technology, University of Delhi. Her field of research is additive manufacturing, friction-based AM, friction stir processing, advanced materials, manufacturing practices, and optimization techniques. She has authored/coauthored around 100 publications in various technical platforms of repute. She has been awarded 18 industrial design patents and 1 copyright.
She has authored/edited seven books in the field of advanced manufacturing. Out of these, three have already been published with CRC press, Taylor & Francis group, and others are either in press or in an accepted stage. Two of them are with Wiley, one with Elsevier, and one with Springer publishing house.
She is working as an editor-in-chief of a book series titled “Advanced Manufacturing of Materials” with CRC Press, Taylor & Francis Group. She has also worked as guest editor for a special issue of a Scopus Indexed Elsevier journal. She is on the editorial board of several reputed journals in the capacity of editorial member. She is also serving as the regional editor of International Journal of Experimental Design & Process Optimization, Inderscience Publishers. Additionally, she is serving as a reviewer in more than 30 Journals. She is working on various projects of around 5 million INR and has completed several consultancy works funded by Govt. of India in the field of Hybrid Additive Manufacturing and rehabilitation robotics. She has a total teaching and research experience of around 15 years. She has won several proficiency awards during the course of her career including merit awards, best teacher awards, etc. One special award that needs mention is the young leader award. She has delivered invited lectures, chaired scientific sessions in several national and international conferences, STTPs, and QIP programs. She is a life member of Additive Manufacturing Society of India (AMSI), Vignana Bharti (VIBHA), The Institution of Engineers (IEI India), Indian Society for Technical Education (ISTE), Indian society of Theoretical and Applied Mechanics (ISTAM), and Indian Institute of Forging (IIF).
Orcid id:https://orcid.org/0000-0001-6513-7882
Dr. J. Paulo Davim is a Full Professor at the University of Aveiro, Portugal. He is also distinguished as honorary professor in several universities/colleges/institutes in China, India, and Spain. He received his PhD degree in Mechanical Engineering in 1997, MSc degree in Mechanical Engineering (materials and manufacturing processes) in 1991, Mechanical Engineering degree (5 years) in 1986, from the University of Porto (FEUP), the Aggregate title (Full Habilitation) from the University of Coimbra in 2005, and the DSc (Higher Doctorate) from London Metropolitan University in 2013. He is Senior Chartered Engineer by the Portuguese Institution of Engineers with an MBA and Specialist titles in Engineering and Industrial Management as well as in Metrology. He is also Eur Ing by Engineers Europe FEANI-Brussels and Fellow (FIET) of IET-London. He has more than 35 years of teaching and research experience in Manufacturing, Materials, Mechanical, and Industrial Engineering, with special emphasis in Machining & Tribology. He has also interest in Management, Engineering Education, and Higher Education for Sustainability. He has guided large numbers of postdoc, PhD, and master’s students as well as has coordinated and participated in several financed research projects. He has received several scientific awards and honors. He has worked as evaluator of projects for ERC-European Research Council and other international research agencies as well as examiner of PhD thesis for many universities in different countries. He is the Editor in Chief of several international journals, Guest Editor of journals, books Editor, book Series Editor, and Scientific Advisory for many international journals and conferences.
Orcid:https://orcid.org/0000-0002-5659-3111
List of Contributors
Mahmoud Abbasi
Department of Materials and Metallurgical Engineering
Amirkabir University of Technology
Tehran
Iran
Bommana B. Abhignya
Department of Mechanical Engineering
Hybrid Additive Manufacturing Laboratory
PDPM Indian Institute of Information Technology
Design and Manufacturing
Jabalpur
India
Shanmugam Arun Kumar
Department of Mechatronics Engineering
Kongu Engineering College
Erode
Tamil Nadu
India
Mohankumar Ashok Kumar
Department of Mechanical Engineering
Government College of Engineering
Anna University
Coimbatore
Tamil Nadu
India
Behrouz Bagheri
Department of Materials and Metallurgical Engineering
Amirkabir University of Technology
Tehran
Iran
Umashankar Bharti
Department of Mechanical Engineering
Hybrid Additive Manufacturing Laboratory
PDPM Indian Institute of Information Technology
Design and Manufacturing
Jabalpur
India
Narendra B. Dahotre
Center for Agile and Adaptive Additive Manufacturing
University of North Texas
Denton
TX
USA
Department of Materials Science and Engineering
University of North Texas
Denton
TX
USA
Kolar Deepak
Department of Mechanical Engineering
Vardhaman College of Engineering
Jawaharlal Nehru Technological University
Hyderabad
Telangana
India
Melaku Desta
Department of Mechanical Engineering
CEME
Addis Ababa Science and Technology University
Addis Ababa
Ethiopia
Devasri Fuloria
School of Mechanical Engineering
Vellore Institute of Technology
Vellore
India
Vijay Shivaji Gadakh
Department of Mechanical Engineering
Dr. Vithalrao Vikhe Patil College of Engineering
Savitribai Phule Pune University
Ahmednagar
Maharashtra
India
Department of Automation and Robotics Engineering
Amrutvahini College of Engineering
Savitribai Phule Pune University
Ahmednagar
Maharashtra
India
Raja Gunasekaran
Department of Mechanical Engineering
Velalar College of Engineering and Technology
Erode
Tamil Nadu
India
Yogesh Ramrao Gunjal
Department of Mechanical Engineering
Dr. Vithalrao Vikhe Patil College of Engineering
Savitribai Phule Pune University
Ahmednagar
Maharashtra
India
Department of Mechanical Engineering
Amrutvahini College of Engineering
Savitribai Phule Pune University
Ahmednagar
Maharashtra
India
Velu Kaliyannan Gobinath
Department of Mechatronics Engineering
Kongu Engineering College
Erode
Tamil Nadu
India
Nikhil Jaiswal
Department of Mechanical Engineering
Hybrid Additive Manufacturing Laboratory
PDPM Indian Institute of Information Technology
Design and Manufacturing
Jabalpur
India
Yuqi Jin
Center for Agile and Adaptive Additive Manufacturing
University of North Texas
Denton
TX
USA
Department of Physics
University of North Texas
Denton
TX
USA
Durairaj Raja Joseph
Department of Aerospace Engineering
School of Aeronautical Sciences
HITS
Hindustan Institute of Technology & Science
Chennai
India
Satish V. Kailas
Department of Mechanical Engineering
IISc
Bangalore
Karnataka
India
Narayan Sahadu Khemnar
Department of Mechanical Engineering
Dr. Vithalrao Vikhe Patil College of Engineering
Savitribai Phule Pune University
Ahmednagar
Maharashtra
India
Department of Automation and Robotics Engineering
Amrutvahini College of Engineering
Savitribai Phule Pune University
Ahmednagar
Maharashtra
India
Atul Kumar
School of Mechanical Engineering
Vellore Institute of Technology
Vellore
India
Gaurav Kumar
Department of Mechanical Engineering
VCE
Dr. A.P.J. Abdul Kalam Technical University
Lucknow
Uttar Pradesh
India
Mukesh Kumar
Department of Mechanical Engineering
VCE
Dr. A.P.J. Abdul Kalam Technical University
Lucknow
Uttar Pradesh
India
Vinayak Malik
Department of Mechanical Engineering
IISc
Bangalore
Karnataka
India
Department of Mechanical Engineering
KLS Gogte Institute of Technology
Visvesvaraya Technological University
Belagavi
Karnataka
India
Neelam Meena
Department of Metallurgical Engineering and Material Science
Indian Institute of Technology Bombay
India
Husain Mehdi
Department of Mechanical Engineering
Meerut Institute of Engineering and Technology
Dr. A.P.J. Abdul Kalam Technical University
Lucknow
Uttar Pradesh
India
Hitesh Mhatre
Department of Mechanical Engineering
Sardar Vallabhbhai National Institute of Technology
Surat
Gujarat
India
Amrut Shrikant Mulay
Department of Mechanical Engineering
Sardar Vallabhbhai National Institute of Technology
Surat
Gujarat
India
Palaniappan Muthukumar
Department of Mechanical Engineering
Kongunadu College of Engineering and Technology
Thottiyam
Tamil Nadu
India
Shazman Nabi
Department of Mechanical Engineering
National Institute of Technology Srinagar
Jammu & Kashmir
India
Farooz A. Najar
Department of Mechanical Engineering
National Institute of Technology Srinagar
Jammu & Kashmir
India
R. Ganesh Narayanan
Department of Mechanical Engineering
Indian Institute of Technology Guwahati
Guwahati
India
Nagarajan Nithyavathy
Department of Mechatronics Engineering
Kongu Engineering College
Erode
Tamil Nadu
Indi
Jinu Paul
Department of Mechanical Engineering
National Institute of Technology Calicut
Calicut
India
Ardula G. Rao
Naval Materials Research Laboratory
Defence Research and Development Organization
Thane
India
Sandeep Rathee
Department of Mechanical Engineering
National Institute of Technology,
Srinagar
Jammu & Kashmir
India
Kazi Sabiruddin
Department of Mechanical Engineering
Indian Institute of Technology Indore
Indore
India
Divya Sachan
Department of Mechanical Engineering
Indian Institute of Technology Guwahati
Guwahati
India
Prem Sagar
Department of Mechanical Engineering
The Technological Institute of Textile Sciences
Maharshi Dayanand University
Rohtak
Haryana
India
Baidehish Sahoo
School of Mechanical Engineering
MIT World Peace University
Pune
India
Mohd Sajid
Department of Mechanical Engineering
VCE
Dr. A.P.J. Abdul Kalam Technical University
Lucknow
Uttar Pradesh
India
Sushma Sangwan
Department of Mechanical Engineering
The Technological Institute of Textile Sciences
Maharshi Dayanand University
Rohtak
Haryana
India
Abhishek Sharma
Research Division of Materials Joining Mechanism
Joining & Welding Research Institute
Osaka University
Osaka
Japan
Arshad N. Siddiquee
Department of Mechanical Engineering
Jamia Millia Islamia
New Delhi
India
Tanvir Singh
Department of Mechanical Engineering
St. Soldier Institute of Engineering & Technology
Punjab Technical University
Jalandhar
Punjab
India
Palani Sivaprakasam
Department of Mechanical Engineering
CEME
Addis Ababa Science and Technology University
Addis Ababa
Ethiopia
Murugan Srinivasan
Department of Mechanical Engineering
Mahendra Engineering College
Anna University
Namakkal
India
Manu Srivastava
Department of Mechanical Engineering
Hybrid additive manufacturing Laboratory
PDPM Indian Institute of Information Technology
Design and Manufacturing
Jabalpur
India
Kandasamy Suganeswaran
Department of Mechatronics Engineering
Kongu Engineering College
Erode
Tamil Nadu
India
Setu Suman
Department of Mechanical Engineering
Indian Institute of Technology Indore
Indore
India
Putti Venkata Siva Teja
Department of Mechanical Engineering
Dhanekula Institute of Engineering & Technology
Jawaharlal Nehru Technological University
Kakinada
Ganguru
Andhra Pradesh
India
Tianhao Wang
Energy and Environment Directorate
Pacific Northwest National Laboratory
Richland
WA
USA
Ashish Yadav
Department of Mechanical Engineering
Hybrid additive manufacturing Laboratory
PDPM Indian Institute of Information Technology
Design and Manufacturing
Jabalpur
India
Teng Yang
Center for Agile and Adaptive Additive Manufacturing
University of North Texas
Denton
TX
USA
Department of Materials Science and Engineering
University of North Texas
Denton
TX
USA
Preface
“This book is dedicated to the relationships of trust and respect that stay strong like an anchor to ward off all obstacles and are a divine intervention to create an oasis of hope in the desert of aimless souls”
Manu
Morally, every researcher and academician is bound to effectively share, exchange, and communicate ideas, knowledge, and experience with the global technical society. The unpredictable nature of life encourages us as an investigator of scientific truths to make every effort to not only share our learnings but also bring together a group of eminent researchers of this technical society to come up with this edited book. This book has contributions from researchers in the field of friction stir welding, processing (FSW/P), and their variants from across the world. The intent is also to facilitate our future generation of researchers with the knowledge gained so far to provide them a consolidation of the accomplished research. This will most definitely empower them with a vision to make a technologically and socially strong community based on deep-rooted foundations. With this thought process in place, the editors have come together to disseminate information gathered from years of experience in the field of FSW/P and their variants with the technical society. Today, a wide variety of high-quality literature in the form of a few monographs and a multitude of journal articles are available in the field of FSW/P, but most of these are confined only to some focused areas. A resource that presents the overall picture in FSW/P and their variants is very much required. This book is a novel venture toward the said direction. It is ensured to present details in simple yet precise language with clarity to cater to a wide variety of readers globally.
FSW is the art and science of joining materials in solid state using a nonconsumable tool with the application of frictional heat. It is frequently utilized for obtaining high-strength welds and join a wide range of materials including but not limited to aluminum and its alloys, copper and its alloys, titanium and its alloys, stainless steel variants, magnesium and its alloys, and so on. When FSW is applied for processing applications or for fabricating composites, the FSW technology is called FSP. With slight modifications, today this technology has more than 25 different variants, each dedicated to some specific applications. At present, FSW/P technology is been increasingly utilized in shipbuilding, aircraft and space applications, welding and processing a variety of exotic and specially engineered structures like shape memory alloys, honey comb, metal matrix, polymer matrix composites, and so on.
This book has 20 chapters each of which is dedicated to a different aspect of FSW/P. The chapters included in this book have been briefly introduced here to make the reader well versed with the overall content.
Chapter 1 presents an overview of friction stir welding technique as a sustainable alternative to conventional metal joining and welding techniques. This chapter also explains the principle and working of FSW, its different variants, and the kind of tool variations incorporated in these variants. Some common defects encountered during FSW are also mentioned. Some of FSW’s advantages and limitations are also added in the end.
Chapter 2 presents an introduction to friction stir welding and the single-point incremental forming procedure on friction stir welded blanks, recent developments in tool design, tool materials, parameter optimization, mechanical properties, etc. The chapter offers quick idea about selection of FSW and SPIF processes to prepare customized components in real-time applications. Two similar or dissimilar materials can be joined and formed with this hybrid manufacturing process. The combined process has versatile applications in automotive and defense sector. SPIF has special advantages over conventional forming processes which includes heterogeneity, quicker lead time, versatility, etc. The chapter concludes with several recommendations for future research.
Chapter 3 presents an overview of friction stir brazing and its variants. Two case studies are presented viz. joining of low carbon steels by application of friction stir brazing and Sn–Pb alloy as filler and intermetallic compound formation and mechanical characteristics of brazed samples made by friction stir vibration brazing with Sn–Pb filler material and SiC reinforcing particles. Applications of friction stir brazing in different sectors are discussed followed by summary and future directions of the chapter.
Chapter 4 introduces and discusses details of friction stir processing (FSP) as a comprehensive microstructure tailoring tool. This chapter starts with the history behind the evolution of the FSP from the conventional friction stir welding processes. The second section of the chapter gives an overview of the working principle of FSP followed by its comparison with other SPD techniques in third section. The fourth section of the chapter elaborates on the factors affecting the process such as tool rotational speed, traverse speed, and in-process cooling. It is followed by discussion related to mechanisms of microstructural evolution. The last section of the chapter describes the challenges and opportunities associated with FSP to resonate with recent trends and become industry ready.
Chapter 5 gives a fundamental overview of friction stir processing along with the process parameters that affect surface integrity. Discussion on the basic mechanism of thermal spray technique along with their classification and applications is provided. Further, discussed the role of surface engineering as a modification technique and how it affects surface morphologies. In the end, the inappropriate parameters that affect the surface modification technique have been assessed.
Chapter 6 deals with surface composites manufacturing by solid-state friction stir processing method. A detailed discussion on the factors affecting the microstructure and mechanical properties of FSPed processed surface composites is provided. This chapter also explains the factors promoting the dominance of various strengthening mechanisms in the surface composites processed through FSP.
Chapter 7 presents the issues in friction stir welding (FSW) of dissimilar material joining such as dissimilar aluminum (Al) alloys, aluminum to copper alloys (Al–Cu), aluminum to titanium (Al–Ti), and aluminum to steel (Al–Fe), recent developments in tool design, tool materials, parameter optimization, microstructure, mechanical properties, common defects occurred, etc. The chapter concludes with several recommendations for future research.
Chapter 8 covers the friction stir welding process, particularly the joining of aluminum and its alloys, which includes the introduction, advancements, applications, and conclusion. Emphasis is given to critical factors that will affect the FSW method in the joining of aluminum alloys. The current state of the art for FSW of aluminum and its alloy, as well as the basics of the process and its influences, are examined. Additionally, additive mixed FSW of Al alloy, testing and characterization like tensile, hardness, and microstructure analysis, as well as industrial applications, are covered in the FSW mechanical characteristics section.
Chapter 9 presents an experimental study on the mechanical characterization of FSWed joints of dissimilar aluminum alloys of AA7050 and AA6082. This work analyzed the effect of processing parameters on the mechanical characterization of the friction stir welded joint (FSWed) of AA7050 and AA6082. Well-material mixing of FSWed joints on high rotational tool speed (RTS) was observed. The fracture of the welded joint at HAZ reveals the excellent weld quality and bonding between the dissimilar metals.
Chapter 10, In this chapter, standard microstructural characterization techniques are presented. Various aspects such as the microstructure sample preparation procedure with brief introduction of equipment used in microstructural characterization are covered. A few illustrative examples are added toward the end of each section of this chapter with an aim to facilitate understanding of concepts.
Chapter 11 focuses on the microstructural characterization and mechanical testing of samples subjected to friction stir welding (FSW) and friction stir processing (FSP) techniques. The aim is to investigate the resulting microstructure and evaluate the mechanical properties of the welded/processed samples. The chapter begins by describing the methodology used for microstructural analysis, which includes techniques such as optical microscopy, scanning electron microscopy (SEM), and X-ray diffraction (XRD). The microstructural features, such as grain structure, grain boundaries, and phase composition, are examined and documented. The findings provide valuable insights into the relationship between process parameters, microstructure, and mechanical behavior, aiding in the optimization of FSW and FSP techniques for desired material properties. In conclusion, this chapter provides a comprehensive analysis of the microstructural characterization and mechanical testing of FSWed/FSPed samples, shedding light on the effects of the welding/processing techniques on the resulting material properties.
Chapter 12 provides state-of-the-art information on the joining of metal matrix-reinforced (MMR) welds by employing the FSW technique. The results are critically evaluated with more emphasis on the reinforcement particles and plasticized material flow behavior that affects the metallurgical properties of MMR welds. In addition, the mechanical performance of reinforced FSW welds is evaluated directly related to welding specifications. Fractography and wear behavior characteristics of reinforced FSW welds are also evaluated based on the materials’ combination of reinforcement particles and base material.
Chapter 13 attempts to summarize the applications, and manufacturing methods of sandwich sheet structures, specifically the solid-state joining methods such as friction stir welding, friction stir spot welding, accumulative roll bonding, and adhesive bonding. Applications in trains, marine sector, turbines, aerospace, and ship construction are presented. From the scarce literature, the problems associated with the manufacturing and joining methods is also highlighted at last.
Chapter 14 provides a bird’s eye view of different types of defects noticed in friction stir welding (FSW). It elaborates on major defects and discusses the possible causes of the emergence of certain types of flaws and the ways to mitigate them. It further exposes the readers to discrete friction stir variants and typical defects observed in these processes. The chapter concludes with a few solutions to avoid defects in friction stir processes.
Chapter 15 explains ultrasound wave propagation behaviors associated with the macrostructure, microstructure, and residual stresses. Then, the explanations of the methodologies are discussed that involved such principles into ultrasonic inspections, evaluations, and monitoring. Furthermore, the cases studies regarding the recent ultrasonic NDT/Es in friction stir-based manufacturing processes are introduced and discussed.
Chapter 16 covers the significance of friction stir welding comparing with other solid-state metal joining processes. The application of FSW on different materials such as aluminum alloys, magnesium alloys, copper alloys, titanium alloys, steels, composite materials, polymers, and plastics is discussed. The recent developments and applications of FSW metal joining process in various industries were also discussed. The industrial applications such as aerospace, automobile, ship building, railways, and other industries were reviewed.
Chapter 17 discusses on the development of an indigenous method of friction stir process (FSP) fabrication technique. A discussion is made on the impetus development of FSP setup to fabricate surface composites with fortified properties for specific applications. Various shoulder and pin profiles have been designed and their effects on the microstructural evolution and mechanical properties were also discussed. The fundamental understanding and critical thinking of the tool modifications and the manufacturing process paves way for the development of new surface composites.
Chapter 18 presents a case study that provides a comprehensive analysis of the effects of various pin profiles on the performance of the FSW tool.
Chapter 19 presents a case study that provides static analysis of honey comb structure (HCS) fabricated by FSP. Several researchers have carried out fabrication of HCS by using FSP method with different materials, but there is meager reported research on its analysis.
Chapter 20 provides a comprehensive review of the friction stir additive manufacturing (FSAM) technique, highlighting its advantages over other gas-/liquid-based technologies. FSAM offers clean and green technology, defect-free parts, cost-effectiveness, and the ability to process intricate designs with excellent mechanical properties. The chapter explores the application of FSAM in the field of additive manufacturing (AM), particularly in complex structural design. The chapter concludes by discussing the microstructural development, recent advancements, and future prospects of FSAM.
The quantum of information related to different friction stir welding/processing techniques, fast degree of obsolescence, and extremely high levels of ongoing technical as well as technological advances puts a restraint on presenting details of every aspect of each related topic. Editor group has, however, put in their best efforts in making this book informative and interesting. This book is a result of dedicated research in the field of FSW/P as well as collaboration with different peer groups and an in-depth literature review. Editors most sincerely hope that the book is a valued knowledge source for upcoming research groups, academia, and industry. It is advised to apply the information in this book for promoting research and development in the field of FSW/P and related processes.
All queries, advice, and observations regarding the book are most welcome.
Dr. Sandeep RatheeDr. Manu SrivastavaDr. J. Paulo Davim
January 2024
Acknowledgments
At the start, our editors Becky Cowan and Lauren Poplawski for being such a huge pillar of strength need a wholehearted acknowledgment. The editors profusely thank the entire team of Wiley Press for their support toward the initiative of bringing forth this book.
The editors thank all the contributing authors of different chapters for sharing their expertise and helping us in bringing the book to its present form. The editors wholeheartedly thank their respective institutions, National Institute of Technology Srinagar, Jammu & Kashmir and PDPM Indian Institute of Information Technology, Design and Manufacturing Jabalpur, Madhya Pradesh. We express deep gratitude to them for their valuable support toward the endeavor to come up with the present edited book.
Dr. Sandeep Rathee wishes to thank his mentors. He also acknowledges the support of his students and family, especially his parents Shri Raj Singh Rathee and Smt. Krishna Rathee, for their constant support.
Dr. Manu Srivastava wishes to thank her mentors. She acknowledges the support of her students for their inspiration and support. Projects like this need a lot of dedicated effort which often comes at the cost of time kept apart for the family. No words of gratitude would suffice to acknowledge the support of her family.
Authors devote and dedicate this work to the Divine Creator based upon their belief that the strength to bring any thoughtful and noble endeavor into being emerges from the Almighty with a wish that this work makes a valuable addition for its readers.
Dr. Sandeep RatheeDr. Manu SrivastavaDr. Paulo Davim
List of Figures
Figure 1.1
Friction stir welding setup.
Figure 1.2
(a) Schematic of FSW process.
Figure 1.3
Various welding zones associated with FSW.
Figure 1.4
Different variants of FSW.
Figure 1.5
Schematics diagram of FSSW: (a) Tool rotation, (b) Plunge, (c) Dwell (stirring action), (d) Retraction.
Figure 1.6
Stationary shoulder FSW.
Figure 1.7
Illustration of FSR for two dissimilar metals: (a) holding of thin sheets, (b) plunging of rivet, (c) generation of heat due to friction, (d) retraction of tool, eventually the above surface rivet is trimmed off from the material surface.
Figure 1.8
Schematic view of FricRiveting process.
Figure 1.9
Friction stir blind riveting.
Figure 1.10
Friction stir scribe: (a) Tool, (b) process.
Figure 1.11
Friction surfacing: (a) the end of the consumable tool, (b) the radial surface of the consumable tool.
Figure 1.12
Schematic arrangement of FSP.
Figure 2.1
Third body area in friction stir welding using (a) a nonconsumable tool and (b) a consumable tool.
Figure 2.2
The FSW process (a) as a schematic and (b) at various phases.
Figure 2.3
Cause–effect diagram.
Figure 2.4
Single-point incremental sheet forming (SPIF).
Figure 2.5
Two-point incremental sheet forming (TPIF).
Figure 2.6
Kinematic incremental sheet forming using two forming tools.
Figure 2.7
Schematic depiction of the SPIF process.
Figure 3.1
Detailed view of the machine used for friction stir vibration brazing.
Figure 3.2
A comparison of interface generation during (a) FSB and (b) FSVB.
Figure 3.3
(a) Temperature variation of joint samples for FSB and FSVB processes. (b) Thermal diffusivity of the joint as a function of vibration frequency.
Figure 3.4
A comparison of microstructure evolution of brazing area fabricated by (a) FSB and (b) FSVB.
Figure 3.5
The distribution of SiO2 nanoparticles in the joint area made by FSVB under various vibration frequencies. (a, b) 20 Hz, (c, d) 35 Hz, and (e, f) 50 Hz.
Figure 3.6
Hardness variation for brazing samples produced by various joining conditions.
Figure 3.7
Fracture surface analysis of the brazing area under different magnifications. (a, b) FSB, (c, d) FSVB. EDS analysis of the noted areas for various joint methods. (e) FSB, (f) FSVB.
Figure 3.8
A comparison of microstructure evolution in the brazing area under various brazing methods. (a) FSB and (b) FSVB.
Figure 3.9
A SEM image of reinforcing distribution in the brazed area under various brazing methods. (a) FSB and (b) FSVB.
Figure 3.10
TEM image of SiC distribution in the brazed samples under various vibration frequencies. (a) 30 Hz, (b) 45 Hz, and (c) 60 Hz.
Figure 3.11
(a) Variation in IMC thickness for top and bottom layer of brazed samples and (b) shear strength of brazed samples under various brazing methods.
Figure 4.1
List of attributes and the potentiality of the FSP as a diversified process.
Figure 4.2
The process illustration of FSP.
Figure 4.3
Optical micrograph of FSPed sample (a) at 720 rpm 85 mm/min, (b) TMAZ, and (c) base metal (Al7075 T651).
Figure 4.4
Effect of processing parameters on shapes of NZ in FSP of cast A356 aluminum at (a) an rpm of 300 and a feed rate of 51 mm/min and (b) an rpm of 900 and a feed rate of 203 mm/min.
Figure 4.5
Classification of FSP process variables.
Figure 4.6
Basic tool geometry along with different types of pin profile and shoulder end surface features.
Figure 4.7
Tool travel patterns for FSP: (a) linear and curved single passes, (b) number of parallel passes at equal space, (c) raster configuration, (d) spiral configuration.
Figure 4.8
