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

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Frictions Stir Process Tool for Surface Modification of Different Alloy: a Review 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 (ductility, 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 metal 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 (Friction Stir Welding) 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. Volume XII Issue VII JULY 2019 Page No: 860 A JOURNAL OF COMPOSITION THEORY ISSN : 0731-6755 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 metals depend upon the process parameters. More heat input is necessary for materials that have high melting 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 Volume XII Issue VII JULY 2019 Page No: 861 A JOURNAL OF COMPOSITION THEORY ISSN : 0731-6755 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. Volume XII Issue VII JULY 2019 Page No: 862 A JOURNAL OF COMPOSITION THEORY ISSN : 0731-6755 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
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