Friction Stir Welding and Processing

About the Editors xv List of Contributors xviii Preface xxv Acknowledgements xxix List of Figures xxx List of Tables xl 1 Friction Stir Welding: An Overview 1 Farooz A. Najar, Shazman Nabi, Sandeep Rathee, and Manu Srivastava 1.1 Introduction 1 1.2 FSW Working Principle 2 1.3 Weld Zones 3 1.4 Variants of FSW 4 1.5 Defects 10 1.6 Advantages and Limitations of FSW 11 1.7 Conclusion and Future Prospectus 12 Acknowledgments 12 References 12 2 Friction Stir Welding and Single-Point Incremental Forming: State-of-the-Art 15 Hitesh Mhatre, Amrut Mulay, and Vijay Gadakh 2.1 Introduction 15 2.2 Friction Stir Welding (FSW) 16 2.3 Single-Point Incremental Forming (SPIF) 18 2.4 FSW and SPIF 21 2.5 Summary and Outlook 22 References 23 3 Friction Stir Brazing and Friction Stir Vibration Brazing 25 Behrouz Bagheri and Mahmoud Abbasi 3.1 Introduction to FSB 25 3.2 Variants of FSB 26 3.3 Two Case studies 27 3.4 Application of FSB and Its Variants in Industry 35 3.5 Summary and Future Directions 35 References 36 4 Fundamentals of Friction Stir Processing 39 Atul Kumar, Devasri Fuloria, Manu Srivastava, and Sandeep Rathee 4.1 Friction Stir Processing (FSP): Background 39 4.2 Working Principle of FSP 39 4.3 Comparison with Other Severe Plastic Deformation (SPD) Techniques 42 4.4 Process Variables 43 4.5 Mechanisms of Microstructural Evolution During FSP 48 4.6 Critical Issues in FSP 49 4.7 Future Scope 50 References 51 5 Role of FSP in Surface Engineering 55 Setu Suman and Kazi Sabiruddin 5.1 Introduction 55 5.2 Role of Surface Modification Techniques 56 5.3 Thermal Spray Technique 57 5.4 FSP – Solid-State Coating Process 58 5.5 Process Parameters of FSP: Surface Engineering 60 5.6 Inappropriate Characteristics of Surface Modification 61 5.7 Summary 63 References 64 6 Surface Composite Fabrication Using FSP 67 Baidehish Sahoo, Jinu Paul, and Abhishek Sharma 6.1 Introduction 67 6.2 Reinforcement Incorporation Approaches 68 6.3 Effect of Process Parameters 71 6.4 Microstructural Evolution and Mechanical Properties 75 6.5 Strengthening Mechanisms 80 6.6 Defects 83 6.7 Summary and Future Directions 86 References 86 7 Friction Stir Welding of Dissimilar Metals 93 Narayan Sahadu Khemnar, Yogesh Ramrao Gunjal, Vijay Shivaji Gadakh, and Amrut Shrikant Mulay 7.1 Introduction 93 7.2 Application Areas of Dissimilar Material Joining 94 7.3 Issues for Dissimilar Material Joining 94 7.4 FSW of Dissimilar Materials 95 7.5 Recent Developments in Tool Design and Tool Materials 103 7.6 Parameter Optimization 103 7.7 Common Defects that Occur in FSW of Dissimilar Metal Joining 104 7.8 Future Recommendations for Dissimilar Metal Joining 105 Acknowledgments 105 References 106 8 Friction Stir Welding of Aluminum and Its Alloy 109 Palani Sivaprakasam, Kolar Deepak, Durairaj Raja Joseph, Melaku Desta, Putti Venkata Siva Teja, and Murugan Srinivasan 8.1 Introduction 109 8.2 Fundamentals of FSW 110 8.3 FSW of Aluminum and Its Alloy 110 8.4 Influences of Process Parameters 112 8.5 Testing and Characterization of FSW of Al and Its Alloy 115 8.6 Additive Mixed Friction Stir Process of Al and Its Alloy 118 8.7 Applications 118 8.8 Conclusions 119 References 119 9 Mechanical Characterization of FSWed Joints of Dissimilar Aluminum Alloys of AA 7050 and AA6082 125 Mohd Sajid, Gaurav Kumar, Husain Mehdi, and Mukesh Kumar 9.1 Introduction 125 9.2 Materials and Methods 126 9.3 Results and Discussion 127 References 131 10 Sample Preparation and Microstructural Characterization of Friction Stir Processed Surface Composites 135 Manu Srivastava, Sandeep Rathee, Shazman Nabi, and Atul Kumar 10.1 Introduction 135 10.2 Sample Preparation for Microscopic Analysis of Metals, Alloys, and Composites 136 10.3 Etching 140 10.4 Microstructural Evolution 141 Acknowledgment 146 References 146 11 Microstructural Characterization and Mechanical Testing of FSWed/FSPed Samples 149 Prem Sagar, Sushma Sangwan, and Mohankumar Ashok Kumar 11.1 Introduction 149 11.2 Microstructural Characterization 152 11.3 Mechanical Testing 159 11.4 Conclusions 162 References 162 12 Comparative Analysis of Microstructural and Mechanical Characteristics of Reinforced FSW Welds 165 Tanvir Singh 12.1 Introduction 165 12.2 Friction Stir Welding (FSW) 166 12.3 Reinforcing Materials-Based Fabrication of FSW Welds 167 12.4 Joinability of Reinforced FSW Welds 168 12.5 Metallurgical Characteristics of FSW Reinforced Welds 169 12.6 Mechanical Behavior of Reinforced FSW Welds 179 12.7 Conclusions 184 12.8 Future Challenges 184 References 185 13 Summary of Efforts in Manufacturing of Sandwich Sheets by Various Joining Methods Including Solid-State Joining Method 193 Divya Sachan, R. Ganesh Narayanan, and Arshad N. Siddiquee 13.1 Introduction 193 13.2 Sandwich Sheets 193 13.3 Classification of Sandwich Sheet Structures 194 13.4 Applications 195 13.5 Fabrication Methods 196 13.6 Summary 200 References 201 14 Defects in Friction Stir Welding and its Variant Processes 205 Vinayak Malik and Satish V. Kailas 14.1 Introduction 205 14.2 General Defects in FSW 205 14.3 Characteristic Defects in Friction Stir Butt and Lap Joints 208 14.4 Distinctive Defects in Major Friction Stir Variants 209 14.5 Solutions to Avoid Defects in Friction Stir-Based Processes 212 14.6 Summary and Concluding Remarks 213 Acknowledgment 213 References 213 15 Nondestructive Ultrasonic Inspections, Evaluations, and Monitoring in FSW/FSP 215 Yuqi Jin, Teng Yang, Narendra B. Dahotre, and Tianhao Wang 15.1 Introduction 215 15.2 Ultrasonic Wave Behaviors in FSWed/FSPed Samples 215 15.3 Common Ultrasonic Inspection and Evaluation Methods for FSWed/FSPed Samples 224 15.4 Case Studies on Recent Novel Ultrasound Evaluation and Monitoring in FSW/FSP 234 15.5 Roles and Potentials of Ultrasound in Future FSW/FSP 242 15.6 Conclusion 243 Acknowledgment 243 References 243 16 Applications of Friction Stir Welding 245 Raja Gunasekaran, Velu Kaliyannan Gobinath, Kandasamy Suganeswaran, Nagarajan Nithyavathy, and Shanmugam Arun Kumar 16.1 Introduction 245 16.2 Application of FSW on Different Materials 247 16.3 Industrial Applications of FSW 252 16.4 Conclusion 255 References 256 17 Equipment Used During FSP 259 Kandasamy Suganeswaran, Nagarajan Nithyavathy, Palaniappan Muthukumar, Shanmugam Arunkumar, and Velu Kaliyannan Gobinath 17.1 Introduction 259 17.2 FSP Experimental Setup 264 17.3 Microstructural Characterization 267 17.4 Mechanical Behavior of Composites Based on Various Tool Shapes 271 17.5 Mechanical behavior of Composites Based on Various Process Parameters 272 17.6 Conclusion 273 References 273 18 Analysis of Friction Stir Welding Tool Using Various Threaded Pin Profiles: A Case Study 275 Bommana B. Abhignya, Ashish Yadav, Manu Srivastava, and Sandeep Rathee 18.1 Introduction 275 18.2 Geometry Considered 277 18.3 Results and Discussions – Analysis in ANSYS 278 18.4 Conclusion 279 Acknowledgement 281 References 281 19 Static Structural and Thermal Analysis of Honeycomb Structure Fabricated by Friction Stir Processing Route: A Case Study 283 Nikhil Jaiswal, Umashankar Bharti, Ashish Yadav, Manu Srivastava, and Sandeep Rathee 19.1 Introduction 283 19.2 Modeling Details 284 19.3 Result and Analysis 286 19.4 Scope of the Case Study 290 19.5 Conclusion 291 Acknowledgement 292 References 292 20 Friction Stir-Based Additive Manufacturing 293 Ardula G. Rao and Neelam Meena 20.1 Additive Manufacturing: An Introduction 293 20.2 Solid-State AM Processes 295 20.3 Case Studies of FSAM on Different Materials 299 20.4 Advantages of FSAM Over Other AM Techniques 300 20.5 Advancements 301 20.6 Limitations 302 20.7 Conclusions and Future prospectives 303 References 303 Index 307