A JOURNAL OF COMPOSITION THEORY ISSN : 0731-6755

Frictions Stir Process Tool for Surface Modification of Different Alloy: A Review

RakeshKumar1 1). Ph.D. Research Scholar, Department of Mechanical Engineering, Chandigarh University, Gharuan, Mohali, Punjab, India. 1) Assistant Professor, Department of Mechanical Engineering, Chandigarh Group of Colleges, Landran, Mohali, Punjab, India.Email: [email protected]

Prabhat Kumar2 2) Assistant Professor, Department of Mechanical Engineering, Chandigarh Group of Colleges, Landran, Mohali, Punjab, India. Email: [email protected]

Santosh Kumar3 3) Ph.D. Research Scholar, Department of Mechanical Engineering, IKG Punjab Technical University, Kapurthala, Punjab, India. 3) , Assistant professor, Department of Mechanical Engineering, Chandigarh Group of Colleges, Landran, Mohali, Punjab, India Email: [email protected]

Abstract- Friction stir processing (FSP) is a solid state process used to improve the local microstructure, mechanical properties (, wear resistance, strength, hardness) and erosion corrosion resistance of similar or dissimilar material but does not weld material together. FSP is carried out to selected depth of the plate thickness and locally eliminates casting defects, increasing fatigue and resistance to corrosion etc. Hence, this paper basically reviews the basic principle, process, and applications of FSP technology as well as its future research directions and development prospects.

Keywords – Friction Stir Processing, Surface Modification, Process Parameters and Applications. 1. INTRODUCTION Material deterioration in the form of corrosion, wear and erosion-corrosion are serious issues in marine environment and accounts for multi-million dollar loss to the relevant industries [1]. Due to the direct impact of hard abrasive particles mixed in a corrosive medium is the main root for deterioration and degradation of marine parts subjected to hydrodynamic conditions [1]. Normally, erosion occurs due to the repetitive impacts of hard erodent particles which ultimately start to severe material loss and surface damage. Erosion-corrosion alone has been reported to be responsible 50-75% of total arrest time in such applications [2]. Overall monetary loss because of different types of corrosion accounts US$ 6500 million annually in India. It has been concluded that surface protection of component used for sea water handling, propulsion & shipping industry is required to avoid their premature failure. Now a day, in naval platforms, thermal spray coatings are commonly applied to solve E-C problems [3-6]. Several authors deposited different coating on marine components using different thermal spray processes to resist E-C problem. The surface coating reduced E-C problem by the development of strongly and stable adherent oxide layer. However, due to existence of lamellar micro structure of thermal sprayed coatings, pores, splat boundaries, and un-melted powder particles results in anisotropic behavior and poor mechanical and tribological characteristics. This results in sudden failure of coating [1]. Hence, changing the surface characteristics of the parent metal itself without altering the surface chemistry is an effective way to solve the above mentioned limitations. Friction Stir Processing (FSP) is an effective way for improving the surface as well as bulk characteristics through micro structural refinement in metal/materials [7-14]. The metallic parts manufactured by casting process are comparatively complex and low cost. In addition, FSP can be utilized to eliminate many of the defects and to create a wrought microstructure into a cast component [15].

1.1 Principle of FSP- FSP works on the principle of FSW () which is a solid state joining method initially developed at the Welding Institute in the U.K. in 1991 [16]. Figure 1 shows the basic principle of FSP.

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Figure 1: Schematics diagram of FSP techniques [17]

Friction stir processing consists of a non-consumable rotating tool, which is inserted into work at the interface surfaces along with axial downward force, until tool shoulder reached the work. In FSP, the tool plays two main roles: heating and deformation of substrate material. The heat is induced mainly because of the friction of the rotating shoulder with the substrate material, while the rotating pin stirs the heated substrate material. Due to this the heated material becomes softens and moves around the rotating probe [17]. Thereafter, the material that flows around the tool is exposed to extreme permanent deformation, which results in a remarkable refinement of microstructure in the processed zone.

1.2 Parameters of FSP- The main parameters of FSP are divided into three different groups as depicted in Fig. 2: a) Machine parameters/variables. b) Tool design specification or parameters. c) Material characteristics.

Figure 2: Types of FSP variables [18]. The important mechanical characteristics of base depend upon the process parameters. More heat input is necessary for materials that have high point namely Cu alloy, Ti alloy steels etc [19].Balasubramanian, V., 2008 [20] explain that major mechanical properties like hardness, yield strength and ductility of base material are essential that control the plastic distortion during FSW. In high heat conductivity materials (titanium alloys, copper alloys and steels), more heat input is essential to achieve defect free processing [21].The greater heat conductivity of metals would allow higher heat

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loss by conduction process [22]. To control thermal characteristics a supporting plate below the work material should be used in SP [23, 24].

a) Machine variables- The important machine variables are traverses speed and rotating rate of the tool. Tool transverse speeds and rotational speeds find some amount of heat developed in the work material [25]. Sufficient amount of heat Produced in stir zone is essential for the development of defect free processing [26].

b) Tool design variables- Tool geometry comprises of shoulder diameter, probe shape, pin feature and size of pin etc. During FSP flow of plasticized metals is mainly influenced by rotational, traverse motion and tool geometry of the FSP tool [27, 28]. Tool angles are very important in FSP because it effect the material flow, heat generation, as well as microstructure etc [26].The effective tilt angle (1-3°) is very essential to keep the work material reservoir below the tool. In addition the use of wide shoulder diameter responsible for high heat development and improve material flow. However, smaller shoulder diameter result in development of shortcoming in the composite material [29].The most important tool materials mainly used in FSP for light alloys are distinct grade steels, whereas harder materials like cermets, tungsten based alloys and Poly cubic boron are used [30].

c) Consequence of cooling- Very small dimensional grains can be attained by sufficient cooling arrangement of materials. Cooling also fulfill the addition function of minimizing the tool wear [31].

1.3 Merits and demerits of FSP-

a) Merits- 1. FSP is a permanent deformation process that causes, metal mixing, and heat exposure, resulting in densification, remarkable micro-structural refinement, and corrosion resistance, improve mechanical properties (tensile strength, micro-hardness, toughness, ductility) and provides homogeneity of the processed zone [32]. 2. FSP is a energy efficient and green method used to enhance resistance to wear, corrosion, creep and fatigue of automotive and aerospace components, without producing any harmful gases and noise [32]. 3. FSP is an economical tool, which require less time for processing and finishing process, environmental friendly [33]. 4. It enhances productivity.

b) Demerits of FSP- Although, FSP has minor limitation, but it can be reduced by further research which includes, need of

backing plate, rigid clamping of the substrate, high initial cost.

II. LITERATURE REVIEW

Various authors used FSP for modification of microstructure and mechanical properties of different alloys which are summarized inTable 1 to Table 3.

Table -1 Application of FSP for Al alloy S.N Authors Year Substrate Tool Profile Parameters Conclusions o. Studied the effect of FSP on Al 1050 alloy in terms of mechanical properties (tensile strength and Rotational speed= hardness) and grain refinement at cylindrical Al 1050 alloy 560–1840 rpm, different rotational speed. The result Kwon et shoulder and a indicates that the tensile strength and 1 2003 (45×100×5mm transverse speed = al. [34] sub conical hardness of the processed alloy ) 155mm/min, single headpin increased by 46 % and 37% pass. respectively at 560 rpm. Also improvement in grain refinement was observed as compared to unprocessed alloy.

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Experimentally examined the influence of FSP on mech. properties A319 and cylindrical of the A356 &A319 alloys. They Tool speed=1000 rpm, Santella et A356 alloys profile with a announced that dendritic translation microstructures were abolished from 2 al. [35] 2005 (3×20×150mm hemispherical speed=1.7mm/s, the stir zone. Also a major ) tip improvementin mechanical properties like fatigue life, tensile strengths and ductility.

straight Investigated the effect of different cylindrical, tool pin profile and rpm on AA 2219 AA 2219 Al tapered Tool speed= 1500, aluminum alloy. From the result it is Elangova alloy cylindrical, 1600,1700 rpm, Axial observed that among all five tool 3. n, K. et al. 2007 profile square pin profile provides (300×150×6m threaded force=12KN, welding [36] better result (defect free FSP zone. m) cylindrical, and speed= 0.76 mm/s. Also at 1600 rpm, the joint fabricated triangular, using square pin profile has higher Square. tensile strength. Straight cylindrical, Among five tool profile and three AA6061 Al Square, Tool speed=1200rpm, Elangova shoulder diameter (15, 18, and alloy threaded welding speed=1.25 n, K.et al. 21mm), the joint fabricated by square 4. 2008 (300×150×6m cylindrical, and mm/min., axial pin profiled tool shoulder having [37] m) triangular, force=7.0 KN, diameter of 18mm exhibit better

tapered tensile properties and produce defect cylindrical. free weld.

The experimental result shows that Tool speed=850rpm, by increasing the number of passes Magdy, Transverse the SZ-grain size also increases. Also 5. M.L. et al. Square pin speed=90,140,224mm re-precipitation and more dissolution 2012 Al alloy 6082. with simultaneous large [38] m/min, No. of fragmentation of 2nd phase particles passes=3. were observed which may be due to concentrated thermal cycles.

flat pinless Tool speed= 945 rpm Improvement in mechanical Fadhel A. AA2024-T3 properties such as hardness (40- 6. 2015 cylindrical and transverse seed = et.al. [39] alloy. 45%), yield strength (15%), tensile shoulder 85mm/min. strength (9%) was noticed using FSP. For pin rotational The experimental result shows that speed = 1600 rpm, AA5083– by increasing the number of passes Traverse speed=20 B4C/SiC/TiC FSP refined the grain structure of Vikram, Pin (taper mm/min, and for pin- Aluminum surface composites. In addition K. et threaded) less rotational speed= higher micro hardness (132.56±2.52), 7. 2018 alloy al.[40] & Pin-less 800rpm and traverse tensile strength (349MPa) was (150×80×6mm speed= 20 mm/min, tilt observed for AA5083– B4C ) angle =3° and no. of composite when compared to the

passes=3 other base alloy composites.

ram speed of 3 mm/s, Significant enhancement in Al-4Mg-1Zr Mishra et width of process zone and elongation 1999 extruded bar (1280%) at 525°C and 1×10-1/s and 8. al. [41] FSP tool = 6 mm, single pass, (10×20mm2) improvement in microstructure tool dia.=5mm, (having grain size=1.5mm).

Tool speed= 1200 to By controlling the heat input in a AZ31B-H24 Straight 2000 rpm, transverse Darras et single pass the fine grain size with 9. 2007 magnesium cylindrical (H- speed=20 to homogenous grain microstructure al. [42] alloy 13 tool steel) 30mm/min, single achieved. pass.

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Table 2: Application of FSP for Cu alloy

S.No. Authors Year Substrate Tool Parameters Conclusions Profile Traverse Produced Cu reinforced MMC using speeds very small size Cr particles by FSP A square =40, 80, so examine consequence of adding and 160 Chromium particles to copper based 11 cylindrical mm/min, matrix. BahramA.Khiyavi et A pure copper 2014 pin tool rotational al., [43] plate 1 with a speed concave =1600 shoulder. mm/min, tilt angle = 1.5°. rotation Multiple pass increase the separation Mohsen Barmouz speed = & dispersion of Silicon carbide and Moham mad 900 rpm, particles & also decreases the 2 2011 Pure copper square pin KazemBesharatiGivi, traverse particle size in the composite matrix. [44] speed = 40mm/min. Rotational, Silicon carbide fragments act as traverse heterogeneous (different) nucleation H.R. Akramifard et Commercially Cylindrical- speed sites in the dynamic re-crystallization 3. 2014 al. [45] pure Cu sheet cone pin =1000 rpm of copper grain. & 50 mm/min Rotational, Observed that with the increase in speed vol. fraction of B4C, the wear rate =1000 and the micro hardness also Commercially rpm, and increased. R. Sathiskumar et Cylindrical 4. 2013 pure copper transverse al.[46] tool plates speed=40 mm/min, axial force = 10 k N.

Table 3: Application of FSP for Cast aluminum alloy

S.No. Authors Year Substrat Tool Profile Parameters Conclusions e A remarkable improvement in fatigue life was noticed, this may Rotational speed=900 Sharma et Cast A356 be due to the development of a fine 1. 2004 Triflute pin rpm, transverse speed= al. [47] Al alloy grain microstructure, reduction in 2mm/min. porosity, and homogeneity of the microstructure. FSP results in reduced Tool densification, porosity and Speed=300rpm&900 Ma, Z.Y. et cast A356 Standard formation in homogeneity in micro- 2. 2006 rpm, transverse al. [48] Al alloy Pin profile structure along with silicon speed=51 to 203 particles ranging from 0.25 to 0.42 mm/min. µm at high speed. At 1800 rpm and 12m/min. feed Tool speed=1400 rpm rate, the processed Al 2285 alloy Karthikeyan, and 1800 rpm, Cast 2285 Cylinderical sample exhibit superior mechanical 3. L. et al . 2009 transverse speed=10,12 alloy pin properties and microstructure ( 30% [49] and 15mm/min., single increase in tensile strength and 4 pass. times in ductility). Tool speed=1400 rpm, Increase in tensile properties of cast Tsai, F.Y. et cast Al-Si Cylindrical 4. 2012 Transverse AC8A alloy by using FSP, mainly al. [50] base alloy pin speed=45mm/min. tensile elongation (< 1% to 15.0%).

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Friction stir processing can be used for manufacturing and refinement in grain structure. In addition, it can also be used for improvement in structure of material (involving super plasticity), homogenization of metal matrix composites and nano-phase Al alloys, surface composite and microstructural refinement of Cu, Al, cast & high strength steel [51].

III. CONCLUSIONS As a novel material-processing technology, FSP has great application value in surface modification of materials and composites fabrication because of its special solid-phase processing mechanism. Compared with traditional composites processing methods, FSP has unique advantages and can be widely applied in the future. After studying the literature it has been concluded that maximum studies are on light weight alloys (Al, Mg, Ti & Be) and very limited work has been done on high strength steel. However, few literatures are on pure erosion or corrosion study of high strength stainless steels. There is very limited experimentation on the combined effect of erosion-corrosion (E-C) performance of . Hence there is a scope to study the effect of FSP on combined effect of E-C, microstructure, and mechanical properties of high strength stainless steels using distinct tool profile and rpm.

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