Friction stir based welding and processing technologies - processes, parameters, microstructures and applications: A review

doi:10.1016/j.jmst.2017.11.029

Abstract

Abstract:

Friction stir welding (FSW) has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys. Conventional FSW, however, has not been entirely successful in the joining, processing and manufacturing of different desired materials essential to meet the sophisticated green globe requirements. Through the efforts of improving the process and transferring the existing friction stir knowledge base to other advanced applications, several friction stir based daughter technologies have emerged over the timeline. A few among these technologies are well developed while others are under the process of emergence. Beginning with a broad classification of the scattered frictions stir based technologies into two categories, welding and processing, it appears now time to know, compile and review these to enable their rapid access for reference and academia. In this review article, the friction stir based technologies classified under the category of welding are those applied for joining of materials while the remnant are labeled as friction stir processing (FSP) technologies. This review article presents an overview of four general aspects of both the developed and the developing friction stir based technologies, their associated process parameters, metallurgical features of their products and their feasibility and application to various materials. The lesser known and emerging technologies have been emphasized.

Key words: Friction stir welding, Friction stir processing, Friction stir scribe, Friction stir riveting, Friction stir channeling, Friction stir forming, Friction stir surfacing, Friction stir additive manufacturing, Friction stir cladding

G.K. Padhy, C.S. Wu, S. Gao. Friction stir based welding and processing technologies - processes, parameters, microstructures and applications: A review[J]. J. Mater. Sci. Technol., 2018, 34(1): 1-38.

Figures/Tables 35

Fig. 1. Classification of friction stir based technologies.

Fig. 2. Third body region in friction stir operations with (a) Non-consumable tool, as in friction stir welding, (b) Consumable tool, as in friction surfacing.

Fig. 3. FSW process (a) schematic [35], and (b) various stages [36].

Fig. 4. Macro-section of friction stir welded joint depicting SAZ, PAZ, WBZ and onion ring features [39].

Fig. 5. (a) Typical weld macrograph of 2024 Al alloy in FSW [63], microstructures of 6061-T6 Al alloy friction stir weld (b) Stir zone, (c) TMAZ, (d) HAZ, and (e) BM [64].

Fig. 6. Schematic diagram of SSFSW [75].

Fig. 7. Optical micrographs of SSFSWed Al 7075-T651 (a) macrograph, (b) BM, (c) TMAZ, (d) HAZ, (e) SZ [72].

Fig. 8. (a) Schematic of RDRFSW; aluminium alloy 2219-T6 welded joint prepared by RDRFSW [77], (b) Macrograph [76], and (c) Microstructure [76].

Fig. 9. Bobbin tool (a) Schematic [89], and (b) photograph [88]; BTFSW process (c) schematic, 1: workpiece, 2: top shoulder, 3: pin, 4: bottom shoulder, 5: acting forces [86], and (d) experimental setup [90].

Fig. 10. Macrograph of weld in BTFSW process [90].

Fig. 11. Schematics of different process stages of (a) FSSW, (b) Refill FSSW [98], and (c) double sided FSSW.

Fig. 12. Short traverse FSSW processes (a) stitch FSSW, and (b) swing FSSW [98].

Fig. 13. Macrograph of a friction stir spot welded 7075-T6 alloy [123], and (b-f) Close up views of different regions in friction stir spot welded 6061-T6 alloy [124].

Fig. 14. Schematic diagrams and types of rivets of the different FSR processes, FricRiveting [137,140], FSBR [142], FSPR [130], RFDR [155] RFPR [156].

Fig. 15. Joint features in different types of FSR processes (a) FricRiveting [139], (b) FSBR [150], (c) FSPR [130], (d) RFDR [155], (e) RFPR [156], and (f) FSR [132].

Fig. 16. (a) FSS tool with single and double scribe cutter [157], and (b) Schematic of FSS process [160].

Fig. 17. Typical macro cross section of FSS weld [159].

Fig. 18. Possibility of IMC layer formation (a) IMC in uncoated steel [165], and (b) IMC in coated steel [166].

Fig. 19. Selected microstructures to show FSP causes (a) grain refinement in Al 7075 alloy [169] (b) Al-Mg-Mn/SiC surface composite formation with good bonding [187], (c) Al3Ti intermetallic particle beak up and homogenization on the surface of Al-Ti-Cu alloy [186] and (d) Uniform distribution of SiC reinforcement particles in Al-matrix in bulk scale [167].

Fig. 20. Superplastic deformation in Al alloy after friction stir processing (a) at 490 °C, (b) at 525 °C, and (c) at a constant strain rate [251,252].

Fig. 21. Schematics of (a) FSC [260], (b) A-FSC [21,264], and (c) M-FSC [275,276] processes.

Fig. 22. Channelled cross section (a) in FSC, where A&B - channel nugget, C - parent material, D - channel, and E - material from the channel nugget deposited on the surface [260], (b) in M-FSC, where SAZ - shoulder affected zone, EZ - extrusion zone, CZ - channel zone [279], and (c) Channel in A-FSC, showing also the [268].

Fig. 23. Channel surface features in (a) FSC [251], and (b) A-FSC [266].

Fig. 24. Friction surfacing process (Figure adopted from [282]) (a) Fixture and set up, (b) Substrate-consumable contact and initial deformation of consumable tip, (c) Consumable deposition on substrate, and (d) Deposit.

Fig. 25. Variation in width and surface finish of deposit with rotation speed [289].

Fig. 26. Variation in quality of H13 mild steel deposit on low carbon steel due to (a) rotation speed, and (b) Travel Speed (Replotted using the data adopted from [294]).

Fig. 27. (.1) Thermo-mechanical events in the FS [287], (.2) Microstructural transformations during the FS of 6XXX Al on 2XXX Al on (a) Consumable base material, (b) heat affected zone, (c) compression-driven TMAZ, (d) torsion-driven TMAZ, (e and f) fully recrystallized microstructure, (g) deposited material and (h) bonding interface [21].

Fig. 28. FSSC process (a) schematic of first approach, (b) side view first approach, (c) schematic of second approach with one cladding rod, and (d) schematic of second approach with two cladding rods [305].

Fig. 29. Microstructure of clad layer interface of AA1050 deposited on the AA2024 substrate (a) double rod cladding and approach 1, (b) double rod cladding and approach 2 and (c) single rod cladding and approach 2 [305].

Fig. 30. Schematics of FSAM (a) rotary friction welding and friction deposition [321], (b) friction deposition and additive manufacturing [322], and (c) additive manufacturing and FSW [323].

Fig. 31. Microstructure of (a) mild steel deposit on mild steel substrate in Type 1 FSAM [321], (b) stainless steel friction surfaced on mild steel in Type1 FSAM multitrack multilayer surfacing [322], and (c) Partial macrostructure of Type 2 FSAM build of Mg alloy [323].

Fig. 32. Macro and microstructures of FSF products (a) Interlocked Cu-wire between superplastic Zn-22Al plates [340], (b) Joining of Al 6014/Mild steel [334], and (c) Fabrication of Cu-W composite [329].

Fig. 33. (a) Schematic of FSE-wire drawing process [352], (b) Schematic of FSE-tubing process [354].

Fig. 34. (a) Schematic of FSE-joining process, (b) Schematic of double-sided FSE-joining process [345].

Fig. 35. Microstructure of (a) Al-tube produced in FSE-tubing [356], and (b) Al wire produced in FSE-wire drawing [348].

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