A Review of Friction Stir Processing of Structural Metallic Materials: Process, Properties, and Methods
Abstract
:1. Introduction
- (1)
- FSP is a solid-state, one-stage processing technique that provides grain refinement, strengthening, and structural homogeneity without changing the shape and size of the processed metallic material [33];
- (2)
- (3)
- the method is both environmentally friendly and energy efficient. FSP has greatly evolved over recent decades and have found many practical and scientific applications [33].
2. Friction Stir Processing
2.1. Principles and Processes
2.2. FSP Process Parameters
2.3. Microstructure in FSP
3. FSP Applications for Different Materials
3.1. FSP of Structural Alloys
3.2. FSP of Aluminum Alloys
3.3. FSP of Copper Alloys
3.4. FSP of Titanium Alloys
3.5. FSP of Magnesium Alloys
4. Friction Stir Processing of Particle-Reinforced Structural Alloys
5. Friction Stir Processing of Structural Alloys for Fabricating In Situ Hybrid Surfaces
6. Conclusions
- (1)
- with a subsurface gradient structure obtained through the formation of equiaxed nanograins and structural homogenization;
- (2)
- with a compositional subsurface gradient structure formed by modifying and hardening the material surface with reinforcing particles;
- (3)
- in situ composites.
Author Contributions
Funding
Conflicts of Interest
Nomenclature
FSP | friction stir processing |
FSW | friction stir welding |
MH | microhardness |
UTS | ultimate tensile strength |
Elong | elongation |
WT | wear testing |
CR | corrosion resistance |
IT | impact toughness |
SWCNTs | single-walled carbon nanotubes |
MWCNT | multi-walled carbon nanotubes |
CNTs | carbon nanotubes |
CS | compressive strength |
HRTEM | high resolution transmission electron microscopy |
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Material | Tool Rotation Rate, rpm | Traverse Speed, mm/min | Number of Passes | Average grain size of the Base Alloy/Average Grain Size after FSP, µm | Mechanical Properties | Ref. No. |
---|---|---|---|---|---|---|
A356 | 350 | 16 | 1 2 3 6 | -/0.74 -/0.58 -/0.45 -/0.51 | MH: 68 HV MH: 92 HV MH: 113 HV MH: 133 HV | [37] |
Al-12Si | 1400 | 28 | 1 | 25/- | MH: ↑ 20.9% UTS: ↑ 15.1% Elong.: ↑ 3.7 times | [38] |
Al5052 | 1120 | 80 | 1 | 243/16.5 | MH: ↑ 13.3% | [59] |
AA5005-H34 | 490 970 1200 | 127 | 1 | -/10.7 -/18.5 -/20.4 | MH: 42.6 HV UTS: 135.3 MPa Elong.: 34.4% MH: 38.9 HV UTS: 118.7 MPa Elong.: 37.3% MH: 37.9 HV UTS: 119.3 MPa Elong.: 41.4% | [40] |
6063 | 300 | 1 2 | 134/5.3 134/8.6 | UTS: ↓ 6% Elong.: ↓ 42% UTS: ↓ 21% Elong.: ↓ 40% | [39] | |
500 | 1 2 | 134/5.5 134/9.6 | UTS: no change Elong.: ↓ 28% UTS: ↓ 10% Elong.: ↓ 29% | |||
700 | 1 2 | 134/7.5 134/9.7 | UTS: ↑ 15% Elong.: ↓ 36% UTS: ↑ 5% Elong.: ↓ 36% | |||
1000 | 1 | 134/8 | - | |||
1200 | 1 | 134/7.8 | - | |||
5086 | 1025 | 30 80 150 | 1 | 48/7 48/10.5 48/3.8 | MH: ↑ 8.6% UTS: ↑ 3.8% Elong.: ↑ 30.7% MH: ↑ 8.6% UTS: ↑ 9.6% Elong.: ↑ 23% MH: ↑ 10% UTS: ↑ 1.9% Elong.: ↑ 19.2% | [43] |
30 80 150 | 12 (intermittent) | 48/8 48/13.5 48/4 | MH: ↑ 6.9% UTS: ↑ 5.7% Elong.: ↑ 40.3% MH: ↑ 5.7% UTS: ↓ 19.2% Elong.: ↑ 19.2% MH: ↑ 5.6% UTS: ↓ 3.8% Elong.: ↑ 15.3% | |||
30 80 150 | 12 (continuous) | 48/10.5 48/15 48/6 | MH: ↓ 4.3% UTS: ↑ 1.9% Elong.: ↑ 32.7% MH: ↑ 1.4% UTS: ↓ 30.8% Elong.: ↑ 3.8% MH: ↑ 4.3% UTS: no change Elong.: ↑ 7.6% | |||
AA1050 | 1600 | 20 | 1 | 42.85/10.58 | MH: ↑ 47.6% CF: ↓ 13.8% | [62] |
Material | Tool Rotation Rate, rpm | Traverse Speed, mm/min | Number of Passes | Average Grain Size of the Base Alloy/Average Grain Size after FSP, µm | Mechanical Properties | Ref. No. |
---|---|---|---|---|---|---|
Cu (99.86%) | 300 | 50 | 1 | 19/9.3 | MH: ↑ 20% UTS: ↑ 18.1% Elong.: ↑ 9% | [47] |
100 | 1 | 19/6.1 | MH: ↑ 21% UTS: ↑ 19.2% Elong.: ↑ 4.5% | |||
150 | 1 | 19/5.9 | MH: ↑ 32% UTS: ↑ 19.6% Elong.: ↑ 4.5% | |||
200 | 1 | 19/3.6 | MH: ↑ 33% UTS: ↑ 19.6% Elong.: ↑ 4.5% | |||
250 | 1 | 19/3.0 | MH: ↑ 34% UTS: ↑ 21.4% Elong.: ↑ 4.5% | |||
Cu (99.99%) | 630 | 40 | 1 4 | 50–60/7.5 50–60/0.7–0.8 | UTS: ↑ 30% Elong.: ↑ 2.9 times UTS: ↑ 43.3% Elong.: ↑ 1.8 times | [110] |
630 | 315 | 1 4 | 50–60/2.5 50–60/4–5 | UTS: ↑ 43.3% Elong.: ↑ 2.4 times UTS: ↑ 43.3% Elong.: ↑ 2.4 times | ||
1600 | 40 | 1 4 | 50–60/6 50–60/2 | UTS: ↑ 46.7% Elong.: ↑ 3.9 times UTS: ↑ 33.3% Elong.: ↑ 4.2 times | ||
Cu (99.95%) | 400 600 800 1200 | 20 | 1 | 15/0.156 15/0.265 15/0.126 15/0.109 | - | [48] |
Cu (99.98%) | 250 350 500 | 50 | 1 | 35/5-20 | MH: ↑ 18.2% UTS: - Elong.: - MH: ↑ 13.4% UTS: ↓ 18.2% Elong.: ↓ 1.7 times MH: ↑ 7.3% UTS: ↓ 17.9% Elong.: ↑ 1.4 times | [49] |
Cu-0.18wt%Zr | 600 | 50 100 150 200 | 1 | 40.5/9.7 40.5/6.6 40.5/4.9 40.5/4.6 | - | [50] |
Material | Tool Rotation Rate, rpm | Traverse Speed, mm/min | Number of Passes | Average Grain Size of the Base Alloy/Average Grain Size after FSP, µm | Mechanical Properties | Ref. No. |
---|---|---|---|---|---|---|
α-Ti (99.6%) | 180 | 25 | 1 | 33.1/5.8 | MH: ↑ 27% YS: ↑ 71.7% UTS: ↑ 35.1% | [51] |
α-Ti (99.85%) | 250 300 350 | 75 | 1 | 42/7 | MH: ↑ 18.4% UTS: 382–384 MPa | [53] |
Ti-6Al-4V | 120 | 30 | 1 | -/0.51 | - | [54] |
Ti grade 2 | 1400 | 14 | 1 2 3 | - | MH: ↑ 15% FC: ↓ 31% MH: ↑ 34.6% FC: ↓ 66% MH: ↑ 55.4% FC: ↓ 88.8% | [55] |
Material | Tool Rotation Rate, rpm | Traverse Speed, mm/min | Number of Passes | Average Grain Size of the Base Alloy/Average Grain Size after FSP, µm | Mechanical Properties | Ref. No. |
---|---|---|---|---|---|---|
Al-Cu-Mg | 450 | - | 1 | 137 × 22.2/9.1 × 6.4 | MH: ↑ 15% UTS: ↑ 9% | [56] |
AZ31 | 200 | 50 | 1 | -/- | UTS: ↑ 4% Elong.: ↑ 9.5% | [129] |
Mg-6Zn-1Y-0.5Zr | 800 | 20 | 1 | -/3.20 | UTS: ↑ 32.6% Elong.: ↑ 146.7% | [128] |
80 | 1 | -/2.37 | UTS: ↑ 37.7% Elong.: ↑ 183.4% | |||
200 | 1 | -/1.65 | UTS: ↑ 53% Elong.: ↑ 151.4% | |||
AZ31 | 400 | 50 | 1 | 16–300/6.6–3.5 | MH: ↑ 22.2% UTS: ↑ 2 times Elong.: ↑ 1.5 times | [127] |
AZ31 | 600 600 600 800 800 800 | 20 30 40 20 30 40 | 1 | -/- | MH: ↑ 17.8% MH: ↑ 24.3% MH: ↑ 38% MH: ↑ 44.6% MH: ↑ 48.7% MH: ↑ 53.7% | [113] |
AZ61 | 1000 | 37 | 2 | 75/0.04–0.2 | MH: ↑ 3 times | [130] |
AZ80 | 375 | 118 | 1 (in air) | -/7.1 | MH: 69.4 HV | [131] |
1 (under water) | -/2.7 | MH: 75.3 HV | ||||
AE42 | 950 | 75 | 1 | 81/7.4 | MH: ↓ 19.1% UTS: ↑ 22.9% Elong.: ↑ 2.7 times | [132] |
QE22 | 800 | 100 | 1 | 38/0.88 | UTS: ↓ 13.5% Elong.: ↑ 3 times | [133] |
800 600 | 100 100 | 1 2 | 38/0.63 | UTS: ↓ 1.9% Elong.: ↑ 3.4 times | ||
800 600 | 100 100 | 1 2 | 38/2.30 | UTS: ↓ 30.7% Elong.: ↑ 1.7 times |
Material | FSP Parameters | Particle Introduction Method | Reinforcing Particles (size) | Average grain Size of the Base Alloy/Average Grain Size after FSP, µm | Mechanical Properties | Ref. No. |
---|---|---|---|---|---|---|
Aluminum alloys | ||||||
Al6061 | 1150 rpm, 31.5 mm/min 1 pass | V-shaped grooves | SiO2 (dav = 20 nm) | -/15,53 | CR: ↑ 78% ↑ MH, UTS, Elong. | [58] |
Al5052 | 1120 rpm, 80 mm/min 1 pass | Groove (depth 2 mm, width 1 mm) | SiC (dav = 5 μm) | 243/5.4 | MH: ↑ 29.3% | [59] |
1120 rpm, 80 mm/min 4 passes | SiC (dav = 5 μm) | 243/4.2 | MH: ↑ 42.6% | |||
1120 rpm, 80 mm/min 4 passes | SiC (dav = 50 nm) | 243/0.9 | MH: ↑ 54.6% | |||
Al6061-T651 | 1000 rpm 72 mm/min 1 pass | Slot in the butt end of the plate | SiC (dav = 3–6 μm) | -/- | UTS: ↓ 28.8% Elong.: ↓ 8.3% | [60] |
1000 rpm 72 mm/min 2 passes | -/- | UTS: ↓ 23% Elong.: ↑ 59.3% | ||||
A356 | 1000 rpm 112 mm/min 1 pass | Groove | 2.5 vol. % Ti3AlC2 | -/- | MH: ↑ 18.4% UTS: ↑ 9% Elong.: ↑ 1.4 times | [61] |
5 vol. % Ti3AlC2 | -/- | MH: ↑ 27.6% UTS: ↑ 14.2% Elong.: ↑ 1.5 times | ||||
7 vol. % Ti3AlC2 | -/- | MH: ↑ 33.8% UTS: ↑ 19.4% Elong.: ↑ 1.7 times | ||||
AA1050 | 1600 rpm 20 mm/min 1 pass | Holes (diameter 2.5 mm, spacing 3 mm) | TiO2 | 42.85/5 | MH: ↑ 61.9% CF: ↓ 19.2% | [62] |
1600 rpm 20 mm/min 2 passes | TiO2 | 42.85/5 | MH: ↑ 80.9% CF: ↓ 29.2% | |||
AA6063 | 1600 rpm 60 mm/min 1 pass | Grooves (1.2 × 5.5 × 100 mm3) | 12 vol. % V (dav = 18 μm) | 72/7.6 | UTS: ↑ 24.6% Elong.: ↑ 1.2 times | [63] |
AA1050 | 1180 rpm 80 mm/min 1 pass | Groove (width 1 mm, depth 3 mm) | Al2O3 | 128/29 128/23 | - | [64] |
1180 rpm 80 mm/min 2 passes | WT: ↑ 1.8 times | |||||
Al2024 | 800 rpm 25 mm/min 1 pass | Groove | Al–10 vol. % Al2O3 powders (dav = 50–150 μm) | 250 × 8/4 | MH: ↑ 2.5 times WT: ↑ 3 times | [65] |
AA6082 | 1250 rpm 40 mm/min 1 pass | - | - | 141/15–20 | MH: ↑ 43.5% WT: ↑ 1.2 times | [66] |
Groove (width 2 mm, depth 2 mm) | CaCO3 (dav = 3–5 μm) | 141/10–12 | MH: ↑ 35.9% WT: ↑ 1.6 times | |||
AA7075 | 1200 rpm 1 pass | Groove | 5 vol. % NbC (dav = 10–20 μm) | 50/40 | UTS: ↑ 13.6% Elong.: ↓ 20% MH: ↑ 17.3% | [76] |
10 vol. % NbC (dav = 10–20 μm) | 50/26 | UTS: ↑ 36.3% Elong.: ↓ 30% MH: ↑ 37.7% | ||||
15 vol. % NbC (dav = 10–20 μm) | 50/16 | UTS: ↑ 47.7% Elong.: ↓ 65% MH: ↑ 53% | ||||
AA7075 | 800 rpm 60 mm/min 1 pass | Hole (diameter 2 mm, depth 3 mm) | - | 82.70/2.98 | MH: ↓ 11.8% IT: ↓ 37.9% | [67] |
MWCNT (diameter 15–20 nm, length 5 μm) | 82.70/2.88 | MH: ↑ 2.8% IT: ↓ 29.7% | ||||
Cu (dav = 10–20 μm) | 82.70/2.57 | MH: ↑ 6.9% IT: ↓ 8.8% | ||||
SiC (dav = 15–20 μm) | 82.70/2.53 | MH: ↑ 2.8% IT: ↓ 6.3% | ||||
AA1060 | 950 rpm 30 mm/min 3 passes | - | - | -/4.8 | UTS: 90.2 MPa Elong.: 36.8% | [68] |
950 rpm 150 mm/min 3 passes | 3 plates, groove in the middle plate (length 150 mm, depth 1.5 mm) | 1.6 vol. % CNT (diameter 12.1 nm, length 1 μm) | -/- | UTS: 102.3 MPa Elong.: 25.3% | ||
600 rpm 95 mm/min 3 passes | -/- | UTS: 103.4 MPa Elong.: 33.4% | ||||
750 rpm 30 mm/min 3 passes | -/- | UTS: 110.9 MPa Elong.: 32.3% | ||||
600 rpm 150 mm/min 3 passes | 3 plates, groove in the middle plate (length 150 mm, depth 2 mm) | 3.2 vol. % CNT (diameter 12.1 nm, length 1 μm) | -/1.9 | UTS: 93.6 MPa Elong.: 32.1% | ||
750 rpm 95 mm/min 3 passes | -/2.1 | UTS: 127 MPa Elong.: 23.3% | ||||
950 rpm 30 mm/min 3 passes | -/3.3 | UTS: 138.8 MPa Elong.: 31.2% | ||||
AA6061 | 1000 rpm 340 mm/min 1 pass | - | - | 70/20 | MH: ↑ 15.4% UTS: ↑ 10% Elong.: ↑ 20.8% CF: ↓ 8.7% | [69] |
1000 rpm 340 mm/min 4 passes | Groove 2 × 3 mm2 | Micro-sized TiB2 particles and nano-sized graphene platelets: 10 wt. % TiB2–0 wt. % graphene | 70/< 1 μm | MH: ↑ 31.6% UTS: ↑ 18.1% Elong.: ↓ 16.6% CF: ↓ 14% | ||
20 wt. % TiB2–0 wt. % graphene | MH: ↑ 48.2% UTS: ↑ 31.3% Elong.: ↓ 25% CF: ↓ 26.3% | |||||
30 wt. % TiB2–0 wt. % graphene | MH: ↑ 45% UTS: ↑ 45% Elong.: ↓ 50% CF: ↓ 7% | |||||
0 wt. % TiB2–0.5 wt. % graphene | MH: ↑ 22.1% UTS: ↑ 37.5% Elong.: ↑ 4.2% CF: ↓ 12% | |||||
0 wt. % TiB2–1 wt. % graphene | MH: ↑ 37.5% UTS: ↑ 54.4% Elong.: ↑ 20.8% CF: ↓ 24.5% | |||||
0 wt. % TiB2–2 wt. % graphene | MH: ↑ 38.5% UTS: ↑ 59.4% Elong.: ↓ 16.7% CF: ↓ 3.5% | |||||
20 wt. % TiB2–0.5 wt. % graphene | MH: ↑ 54.4% UTS: ↑ 61.9% Elong.: ↓ 8.3% CF: ↓ 29.8% | |||||
20 wt. % TiB2–1 wt. % graphene | MH: ↑ 66.5% UTS: ↑ 69.4% Elong.: ↓ 4.2% CF: ↓ 29.6% | |||||
20 wt. % TiB2–2 wt. % graphene | MH: ↑ 62.8% UTS: ↑ 75.6% Elong.: ↓ 62.5% CF: ↓ 1.7% | |||||
Al7005 | 750 rpm 50 mm/min 2 passes | - | - | -/- | MH: ↑ 33.3% | [70] |
Holes (diameter 1.5 mm, depth 3 mm) | 50% B4C + 50% TiB2 | -/- | MH: ↑ 66.6% | |||
75% B4C + 25% TiB2 | -/- | MH: ↑ 64.4% | ||||
25% B4C + 75% TiB2 | -/- | MH: ↑ 61.1% | ||||
Copper alloys | ||||||
Cu (99.9%) | 1000 rpm 40 mm/min 1 pass | Groove (depth 2.5 mm, width 0.7 mm) | 12 vol. % SiC | 35/6 | MH: ↑ 54.6% | [71] |
12 vol. % Al2O3 | 35/3 | MH: ↑ 58.6% | ||||
12 vol. % B4C | 35/5 | MH: ↑ 80% | ||||
12 vol. % TiC | 35/4 | MH: ↑ 68% | ||||
Cu (99.9%) | 710 rpm 20 mm/min 1 pass | - | - | 30/21 | MH: ↑ 8% UTS: ↑ 2.5% Elong.: ↓ 1.9 time CF: ↓ 14% | [72] |
710 rpm 20 mm/min 1 pass | Holes (depth 3 mm, length 2 mm, spacing 4 mm) | TiO2 (dav = 41 nm) | 30/9.3 | MH: ↑ 28.3% UTS: ↑ 22.6% Elong.: ↓ 2.7 time CF: ↓ 48.4% | ||
710 rpm 20 mm/min 2 passes | 30/6.4 | MH: ↑ 50% UTS: ↑ 27.6% Elong.: ↓ 3.5 time CF: ↓ 60.9% | ||||
710 rpm 20 mm/min 4 passes | 30/2.4 | MH: ↑ 77% UTS: ↑ 33% Elong.: ↓ 2.4 time CF: ↓ 75% | ||||
Cu | 1000 rpm 30 mm/min 1 pass | Groove | AlN (dav = 10 μm), BN (dav = 1 μm): 5 vol. % (25 mass. % AlN + 75 mass. % BN) | -/- | MH: ↑ 25% UTS: ↓ 26.6% Elong.: ↓ 1.4 times | [73] |
AlN (dav = 10 μm), BN (dav = 1 μm): 10 vol. % (25 mass. % AlN + 75 mass. % BN) | -/- | MH: ↑ 28.3% UTS: ↓ 19.7% Elong.: ↓ 1.5 times | ||||
AlN (dav = 10 μm), BN (dav = 1 μm): 15 vol. % (25 mass. % AlN + 75 mass. % BN) | -/- | MH: ↑ 29.2% UTS: ↓ 19.7% Elong.: ↓ 2.3 time | ||||
Titanium alloys | ||||||
CP-Ti | 800 rpm 45 mm/min 3 passes | - | - | 75/4 | MH: ↑ 56.2% | [140] |
500 rpm 50 mm/min 4 passes | Grooves (width 2 mm, depth 2 mm) | β-SiC powder (dav = 50 nm) | 75/0.4 | MH: ↑ 228% | ||
CP-Ti grade 2 | 500 rpm 50 mm/min 1 pass | - | - | 28/4.4 | - | [141] |
500 rpm 50 mm/min 4 passes | - | - | 28/2.6 | - | ||
500 rpm 50 mm/min 1 pass | Groove (width 1 mm, depth 3 mm) | ~1.8 vol. % Al2O3 (dav = 80 nm) | 28/1.14 | - | ||
Magnesium alloys | ||||||
AZ31B | 1000 rpm 40 mm/min 3 passes | Groove 2 × 4 mm2 | 1.6 vol. % MWCNT (dav = 10–30 nm) + 0.3 vol. % graphene (dav = 5–10 nm) | -/- | [74] | |
1200 rpm 40 mm/min 3 passes | -/- | |||||
1400 rpm 40 mm/min 3 passes | -/- | |||||
Mg + 5 wt. % (SiC + Al2O3) | SiC and Al2O3 hybrid particles were added to molten metal at 700 °C. The mixture was stirred for 20 min at 400 rpm with a stirrer, followed by pouring into a permanent mould | Casting | 5 wt. % (SiC + Al2O3) | 82 | MH: 59.3 HV | [75] |
220 rpm 10 mm/min 1 pass | 82/15 | MH: ↑ 13.9% | ||||
340 rpm 20 mm/min 1 pass | 82/11 | MH: ↑ 15.5% | ||||
560 rpm 30 mm/min 1 pass | 82/7 | MH: ↑ 17.5% |
Material | FSP Parameters | Particle Introduction Method | Introduced Particles (Size) | Average Grain Size of the Base Alloy/Average Grain Size after FSP, µm | Formation of Additional/Intermetallic Phases | Mechanical Properties | Ref. No. |
---|---|---|---|---|---|---|---|
Aluminum alloys | |||||||
7075 | 1200 rpm 30 mm/min 1 pass | Groove (width 3 mm, depth 3 mm) | Ti-6Al-4V (dav = 35 nm) | -/- | Al3Ti AlTi AlTi3 | MH: ↑ 3.3% UTS: ↑ 7.4% Elong.: ↑ 1.2 times FC: 0.7 | [78] |
1200 rpm 30 mm/min 2 passes | Ti-6Al-4V (dav = 35 nm) | -/- | Al3Ti AlTi AlTi3 | MH: ↑ 28.3% UTS: ↑ 23.5% Elong.: ↑ 2 times FC: 0.58 | |||
1200 rpm 30 mm/min 3 passes | Ti-6Al-4V (dav = 35 nm) | -/- | Al3Ti AlTi AlTi3 | MH: ↑ 60% UTS: ↑ 38.8% Elong.: ↑ 2.1 times FC: 0.32 | |||
AA1050 | 1400 rpm 40 mm/min 2 passes | Holes (diameter 2 mm, depth 3 mm | Ni (≤ 20 μm), Ti (40-60 μm), C (50 μm). Powder mixture Ni-32 mass. % Ti-8 mass. % C. Preliminary planetary ball milling | -/- | Al3Ni TiC | - | [79] |
1400 rpm 40 mm/min 4 passes | -/- | Al3Ni TiC | - | ||||
1400 rpm 40 mm/min 6 passes | -/- | Al3Ni TiC | MH: ↑ 214% | ||||
Al6061-T651 | 1000 rpm 72 mm/min 1 pass | Slot in the butt end of the plate | SiC (dav = 3-6 μm) with 1.3–1.8 µm thick copper coating | -/- | Al2Cu Al4Cu9 | MH: ↓ 11% UTS: ↓ 24.6% Elong.: ↑ 18.7% | [60] |
1000 rpm 72 mm/min 2 passes | SiC (dav = 3–6 μm) with 1.3–1.8 µm thick copper coating | -/- | Al2Cu Al4Cu9 | MH: ↑ 16.6% UTS: ↓ 15% Elong.: ↑ 29.6% | |||
A356 | 1600 rpm 50 mm/min 1 pass | Groove (width 0.6 mm, depth 3.5 mm) | Powder mixture SiCp (dav = 30 μm) ‒ MoS2 (dav = 5 μm) | Destruction of needle-like Si and Al dendrites | SiCp and MoS2 particles (dav ~10 μm) | MH: ↑ 45.4% FC: ↓ 2 times | [80] |
1600 rpm 50 mm/min 1 pass | Groove (width 0.6 mm, depth 3.5 mm) | SiCp (dav = 30 μm) | Destruction of needle-like Si and Al dendrites | SiCp particles (dav ~10 μm) | MH: ↑ 54.5% | ||
A6061 | 1600 rpm 60 mm/min 2 passes | Groove dimensions correspond to 18 vol.% of reinforcing particles | 18 vol. % fly ash (dav = 5 μm) | 76.85/5.61 | Uniform distribution of fly ash particles independently of the metal matrix type | MH: ↑ 2 times | [81] |
1050 | 1120 rpm 125 mm/min 4 passes | Groove (depth 3.5 mm, width 1.4 mm) | Powder mixture Fe2O3 (dav = 1 μm) ‒ Al (dav = 100 μm), pre-mixed and pre-ground | -/~2–3 | Al13Fe4 (~100 nm) α-Al2O3, Fe3O4 | MH: ↑ 27.3% | [82] |
Al-1050-H24 | 750 rpm 99.4 mm/min | Groove (width 3 mm, depth 1.5 mm) | Cu powder (dav = 5 μm) | -/- | CuAl2 Al-Cu Al4Cu9 | MH: ↑ 4 times | [83] |
750 rpm 49.7 mm/min | -/- | MH: ↑ 5 times | |||||
A413 | 2000 rpm 8 mm/min 1 pass | Groove 2 × 3 mm2 | Ni powder (dav = 1–3 μm) | Si: 40.6/4.58 | Al3Ni | MH: ↑ 18.8% CF: ↓ 1.5 times | [84] |
2000 rpm 8 mm/min 3 passes | Si: 40.6/2.8 | MH: ↑ 26.5% CF: ↓ 1.5 times | |||||
Al1100 | 1180 rpm 60 mm/min 2 passes | Groove (width 3 mm, depth 5 mm) | Ni powder (dav = 25–38 μm) | -/- | Nonuniform distribution of a small amount of Al3Ni particles | MH: ↑ 1.8 times UTS: ↑ 1.5 times Elong.: ↓ 1.9 times | [85] |
1180 rpm 60 mm/min 4 passes | -/- | More uniform distribution of Al3Ni | MH: ↑ 2.5 times UTS: ↑ 1.8 times Elong.: ↓ 3.5 times | ||||
1180 rpm 60 mm/min 6 passes | -/- | Uniform Al3Ni distribution (dav ≤ 1 μm) | MH: ↑ 2.7 times UTS: ↑ 1.9 times Elong.: ↓ 3.9 times | ||||
Al1050 | 1600 rpm 20 mm/min 2 passes | Groove 1 × 2 × 160 mm3 | Nb powder (d = 1–10 μm) | 60/23 | Al3Nb Al3Nb Al3Nb | MH: ↑ 13.6% UTS: ↑ 13.3% Elong.: ↓ 2.5 times | [86] |
1600 rpm 20 mm/min 4 passes | Groove 1 × 2 × 160 mm3 | 60/6.5 | MH: ↑ 54.5% UTS: ↑ 33.3% Elong.: ↓ 1.6 times | ||||
1600 rpm 20 mm/min 4 passes | Groove 2 × 2 × 160 mm3 | 60/4 | MH: ↑ 100% UTS: ↑ 33.3% Elong.: ↓ 2 times | ||||
AA5052 | 1250 rpm 25 mm/min 1 pass | - | - | 10.7/9.7 | - | MH: ↑ 9% UTS: ↑ 14.4% Elong.: ↓ 3.4% | [87] |
1200 rpm 100 mm/min 5 passes | Groove (width 1.2 mm, depth 3.5 mm) | Powders of graphene nanoplatelets (diameter 2 μm, thickness 1–20 nm) | 10.7/2.1 | (Fe,Mn,Cr)3SiAl12 particles (dav ≤ 1 μm), Al4C3 particles | MH: ↑ 52.7% UTS: ↑ 35.7% Elong.: ↓ 31.8% | ||
Copper alloys | |||||||
Cu plate (99.9% pure) | 1000 rpm 40 mm/min 2 passes | Groove dimensions correspond to 18 vol. % of reinforcing particles | 18 vol. % fly ash (dav = 5 μm) | 35.43/2.79 | Uniform distribution of fly ash particles independently of the metal matrix type | MH: ↑ 2.13 times | [81] |
Titanium alloys | |||||||
Ti-6Al-4V | 800 rpm 25 mm/min 1 pass | - | - | -/- | - | MH: ↑ 5.4% CS: ↑ 1.7% | [88] |
Holes (diameter 1.2 mm, depth 3.8 mm, spacing 2.5 mm) | B4C (dav = 10 μm) | -/- | TiB, TiB2, TiC | MH: ↑ 68% CS: ↑ 47.9% | |||
Ti | 1200 rpm 50 mm/min 1 pass | - | - | 92.2/~2 | - | MH: ↑ 25.5% UTS: ↑ 28.8% Elong.: ↓ 33.7% | [89] |
Groove (length 210 mm, width 1.2 mm, depth 3.5 mm) | Hydroxy-apatite powder Ca10(PO4)6(OH)2 (dav = 120 nm) | 92.2/1.4–14.8 | Decomposition products in the form of elemental calcium (Ca) and phosphide (PO3) | MH: ↑ 34.8% UTS: ↓ 41.6% Elong.: ↓ 52.2% | |||
Magnesium alloys | |||||||
AZ31 | 1200 rpm 40 mm/min 2 passes | Groove dimensions correspond to 18 vol.% of reinforcing particles | 18 vol.% fly ash (dav = 5 μm) | 66.35/6.09 | Uniform distribution of fly ash particles independently of the metal matrix type | MH: ↑ 1.75 times | [81] |
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Zykova, A.P.; Tarasov, S.Y.; Chumaevskiy, A.V.; Kolubaev, E.A. A Review of Friction Stir Processing of Structural Metallic Materials: Process, Properties, and Methods. Metals 2020, 10, 772. https://doi.org/10.3390/met10060772
Zykova AP, Tarasov SY, Chumaevskiy AV, Kolubaev EA. A Review of Friction Stir Processing of Structural Metallic Materials: Process, Properties, and Methods. Metals. 2020; 10(6):772. https://doi.org/10.3390/met10060772
Chicago/Turabian StyleZykova, Anna P., Sergei Yu. Tarasov, Andrey V. Chumaevskiy, and Evgeniy A. Kolubaev. 2020. "A Review of Friction Stir Processing of Structural Metallic Materials: Process, Properties, and Methods" Metals 10, no. 6: 772. https://doi.org/10.3390/met10060772