Friction stir additive manufacturing was employed to fabricate a SiC-reinforced AA6061 composite. The tool with a pin length of 4.5 mm (plunge depth of 50% into the lower layer thickness) was used for the experiment. The stir zone consisted of fine, equiaxed grains due to dynamic recrystallisation. Variations in grain size, as well as changes in precipitate distribution, size, and morphology, were detected along the build direction. Hardness and tensile strength varied across layers, with the top slice having the greatest values of 104.2 HV and 268.4 MPa, respectively. Notably, the FSAM build demonstrated improved ductility with a maximum of 58.98%, mostly ascribed to fragmentation and partial loss of grain-boundary phases, as well as strong interfaces that delayed necking.
LesuerD, SynCK, SherbyOD, . Mechanical behaviour of laminated metal composites. Int Mater Rev. 1996;41(5):169–197. doi:10.1179/imr.1996.41.5.169
2.
CarreñoF, ChaoJ, PozueloM, . Microstructure and fracture properties of an ultrahigh carbon steel–mild steel laminated composite. Scr Mater. 2003;48(8):1135–1140. doi:10.1016/S1359-6462(02)00602-4
3.
BeygiR, KazeminezhadM, KokabiA.Microstructural evolution and fracture behavior of friction-stir-welded Al-Cu laminated composites. Metall Mater Trans A. 2014;45(1):361–370. doi:10.1007/s11661-013-1989-z
4.
PozueloM, CarreñoF, RuanoOA.Delamination effect on the impact toughness of an ultrahigh carbon–mild steel laminate composite. Compos Sci Technol. 2006;66(15):2671–2676. doi:10.1016/j.compscitech.2006.03.018
5.
PalanivelS, MishraRS.Building without melting: a short review of friction-based additive manufacturing techniques. Int J Additive Subtractive Materials Manuf. 2017;1(1):82–103. doi:10.1504/IJASMM.2017.082991
6.
RatheeS, MaheshwariS, SiddiqueeAN, . A review of recent progress in solid state fabrication of composites and functionally graded systems via friction stir processing. Crit Rev Solid State Mater Sci. 2018;43(4):334–366. doi:10.1080/10408436.2017.1358146
7.
SrivastavaM, RatheeS, MaheshwariS, . A review on recent progress in solid state friction based metal additive manufacturing: friction stir additive techniques. Crit Rev Solid State Mater Sci. 2019;44(5):345–377. doi:10.1080/10408436.2018.1490250
8.
WeiJ, HeC, QieM, . Achieving high performance of wire arc additive manufactured Mg–Y–Nd alloy assisted by interlayer friction stir processing. J Mater Process Technol. 2023;311:117809–117821. doi:10.1016/j.jmatprotec.2022.117809.
RatheeS, SrivastavaM, PandeyPM, . Metal additive manufacturing using friction stir engineering: a review on microstructural evolution, tooling and design strategies. CIRP J Manuf Sci Technol. 2021;35:560–588. doi:10.1016/j.cirpj.2021.08.003
11.
RatheeS, . Friction based additive manufacturing technologies: principles for building in solid state, benefits, limitations, and applications. Boca Raton: CRC Press; 2018.
12.
CederqvistL, ReynoldsA.Factors affecting the properties of friction stir welded aluminum lap joints. Weld J. 2001;80(12):281-s–287-s.
13.
CaoX, JahaziM.Effect of tool rotational speed and probe length on lap joint quality of a friction stir welded magnesium alloy. Mater Des. 2011;32(1):1–11. doi:10.1016/j.matdes.2010.06.048
14.
YazdanianS, ChenZ, LittlefairG.Effects of friction stir lap welding parameters on weld features on advancing side and fracture strength of AA6060-T5 welds. J Mater Sci. 2012;47:1251–1261. doi:10.1007/s10853-011-5747-6
15.
PalanivelS, NelaturuP, GlassB, . Friction stir additive manufacturing for high structural performance through microstructural control in an Mg based WE43 alloy. Mater Des. 2015;65:934–952. doi:10.1016/j.matdes.2014.09.082
16.
YuqingM, LimingK, ChunpingH, . Formation characteristic, microstructure, and mechanical performances of aluminum-based components by friction stir additive manufacturing. Int J Adv Manuf Technol. 2016;83(9):1637–1647. doi:10.1007/s00170-015-7695-9
17.
HeC, LiY, ZhangZ, . Investigation on microstructural evolution and property variation along building direction in friction stir additive manufactured Al–Zn–Mg alloy. Mater Sci Eng A. 2020;777:139035–139047. doi:10.1016/j.msea.2020.139035
18.
ZhaoZ, YangX, LiS, . Interfacial bonding features of friction stir additive manufactured build for 2195-T8 aluminum-lithium alloy. J Manuf Process. 2019;38:396–410. doi:10.1016/j.jmapro.2019.01.042
19.
WlodarskiS, AveryDZ, WhiteBC, . Evaluation of grain refinement and mechanical properties of additive friction stir layer welding of AZ31 magnesium alloy. J Mater Eng Perform. 2021;30:964–972. doi:10.1007/s11665-020-05394-5
20.
JiangT, JiaoT, DaiG, . Microstructure evolution and mechanical properties of 2060 Al-Li alloy via friction stir additive manufacturing. J Alloys Compd. 2023;935:168019–168029. doi:10.1016/j.jallcom.2022.168019
21.
ThangarasuA, MuruganN, DinaharanI, . Synthesis and characterization of titanium carbide particulate reinforced AA6082 aluminium alloy composites via friction stir processing. Arch Civ Mech Eng. 2015;15(2):324–334. doi:10.1016/j.acme.2014.05.010
22.
BahramiM, NikooMF, GiviMKB.Microstructural and mechanical behaviors of nano-SiC-reinforced AA7075-O FSW joints prepared through two passes. Mater Sci Eng A. 2015;626:220–228. doi:10.1016/j.msea.2014.12.009
23.
JhaKK, KesharwaniR, ImamM.Microstructure, texture, and mechanical properties correlation of AA5083/AA6061/SiC composite fabricated by FSAM process. Mater Chem Phys. 2023;296:127210–127222. doi:10.1016/j.matchemphys.2022.127210
24.
SrivastavaM, RatheeS.Microstructural and microhardness study on fabrication of Al 5059/SiC composite component via a novel route of friction stir additive manufacturing. Mater Today Proc. 2021;39:1775–1780. doi:10.1016/j.matpr.2020.07.137
25.
PradoR, MurrLE, ShindoDJ, . Tool wear in the friction-stir welding of aluminum alloy 6061 + 20% Al2O3: a preliminary study. Scr Mater. 2001;45(1):75–80. doi:10.1016/S1359-6462(01)00994-0
26.
AcharyaU, RoyBS, SahaSC.A study of tool wear and its effect on the mechanical properties of friction stir welded AA6092/17.5 Sicp composite material joint. Mater Today Proc. 2018;5(9):20371–20379. doi:10.1016/j.matpr.2018.06.412
27.
AshishB, SainiJ, SharmaB.A review of tool wear prediction during friction stir welding of aluminium matrix composite. Trans Nonferrous Met Soc China. 2016;26(8):2003–2018. doi:10.1016/S1003-6326(16)64318-2
28.
IkhsanM, SyamsudinH, SuadaM.Stiffened panel structural optimization on wing skin of “WHALE” aircraft with local and global buckling criteria. Journal of physics: conference series. IOP Publishing; 2018.
29.
AverardiA, ColaC, ZeltmannSE, . Effect of particle size distribution on the packing of powder beds: a critical discussion relevant to additive manufacturing. Mater Today Commun. 2020;24:100964–100980. doi:10.1016/j.mtcomm.2020.100964
30.
SalariE, JahaziM, KhodabandehA, . Influence of tool geometry and rotational speed on mechanical properties and defect formation in friction stir lap welded 5456 aluminum alloy sheets. Mater Des. 2014;58:381–389. doi:10.1016/j.matdes.2014.02.005
31.
FathiJ, EbrahimzadehP, FarasatiR, . Friction stir welding of aluminum 6061-T6 in presence of watercooling: analyzing mechanical properties and residual stress distribution. Int J Lightweight Mater Manuf. 2019;2(2):107–115. doi:10.1016/j.ijlmm.2019.04.007
32.
XuW, LiuJH, ChenDL, . Improvements of strength and ductility in aluminum alloy joints via rapid cooling during friction stir welding. Mater Sci Eng A. 2012;548:89–98. doi:10.1016/j.msea.2012.03.094
33.
KumarK, KailasSV.The role of friction stir welding tool on material flow and weld formation. Mater Sci Eng A. 2008;485(1-2):367–374. doi:10.1016/j.msea.2007.08.013
34.
SuttonMA, YangB, ReynoldsAP, . Microstructural studies of friction stir welds in 2024-T3 aluminum. Mater Sci Eng A. 2002;323(1-2):160–166. doi:10.1016/S0921-5093(01)01358-2
35.
AgilanM, PhanikumarG, SivakumarD.Tensile behaviour and microstructure evolution in friction stir welded 2195–2219 dissimilar aluminium alloy joints. Weld World. 2022;66(2):227–237. doi:10.1007/s40194-021-01217-w
36.
Da SilvaA, ArrutiE, JaneiroG, . Material flow and mechanical behaviour of dissimilar AA2024-T3 and AA7075-T6 aluminium alloys friction stir welds. Mater Des. 2011;32(4):2021–2027. doi:10.1016/j.matdes.2010.11.059
37.
SunW, ZhangW, GuoJ, . Cracking behavior in tensile and bending test of underwater explosive-welded AZ31/Cu laminated composite. Theor Appl Fract Mech. 2019;103:102256–102263. doi:10.1016/j.tafmec.2019.102256
38.
HamdollahzadehA, BahramiM, Farahmand NikooM, . Microstructure evolutions and mechanical properties of nano-SiC-fortified AA7075 friction stir weldment: the role of second pass processing. J Manuf Process. 2015;20:367–373. doi:10.1016/j.jmapro.2015.06.017
39.
JhaKK, KesharwaniR, ImamM.Microstructural and micro-hardness study on the fabricated Al 5083-O/6061-T6/7075-T6 gradient composite component via a novel route of friction stir additive manufacturing. Mater Today Proc. 2022;56:819–825. doi:10.1016/j.matpr.2022.02.262
40.
BagheriB, AbbasiM.Development of AZ91/SiC surface composite by FSP: effect of vibration and process parameters on microstructure and mechanical characteristics. Adv Manuf. 2020;8(1):82–96. doi:10.1007/s40436-019-00288-9
41.
OgunsemiBT, AbioyeTE, OgedengbeTI, . A review of various improvement strategies for joint quality of AA 6061-T6 friction stir weldments. J Mater Res Techno. 2021;11:1061–1089. doi:10.1016/j.jmrt.2021.01.070
42.
ChoudhuryS, . Recent progress in solid-state additive manufacturing technique: friction stir additive manufacturing. Proceedings of the institution of mechanical engineers. Part E: J Process Mech Eng. 2022;237(2):467–491. doi:10.1177/09544089221107755
43.
MaoY, KeL, LiuF, . Effect of tool pin eccentricity on microstructure and mechanical properties in friction stir welded 7075 aluminum alloy thick plate. Mater Des. 2014;62:334–343. doi:10.1016/j.matdes.2014.05.038
44.
JhaKK, KesharwaniR, ImamM.Microstructure and mechanical properties correlation of FSAM employed AA5083/AA7075 joints. Trans Indian Inst Met. 2023;76(2):323–333. doi:10.1007/s12666-022-02672-9
45.
PrangnellP, HeasonC.Grain structure formation during friction stir welding observed by the ‘stop action technique’. Acta Mater. 2005;53(11):3179–3192. doi:10.1016/j.actamat.2005.03.044
46.
van HuisM, ChenJH, SluiterMHF, . Phase stability and structural features of matrix-embedded hardening precipitates in Al–Mg–Si alloys in the early stages of evolution. Acta Mater. 2007;55(6):2183–2199. doi:10.1016/j.actamat.2006.11.019
47.
RaviC, WolvertonC.First-principles study of crystal structure and stability of Al–Mg–Si–(Cu) precipitates. Acta Mater. 2004;52(14):4213–4227. doi:10.1016/j.actamat.2004.05.037
48.
MurayamaM, HonoK.Pre-precipitate clusters and precipitation processes in Al–Mg–Si alloys. Acta Mater. 1999;47(5):1537–1548. doi:10.1016/S1359-6454(99)00033-6
49.
IkenoKMS, SatoT.HRTEM study of nano-precipitation phases in 6000 series aluminum alloys. In: Mendez-VilasAntonio, editor. Science, Technology and Education of Microscopy: an Overview. Formatex; 2003. p. 152–162.
50.
MaisonnetteD, SueryM, NeliasD, . Effects of heat treatments on the microstructure and mechanical properties of a 6061 aluminium alloy. Mater Sci Eng A. 2011;528(6):2718–2724. doi:10.1016/j.msea.2010.12.011
51.
LiuG, MurrLE, NiouC-S, . Microstructural aspects of the friction-stir welding of 6061-T6 aluminum. Scr Mater. 1997;37(3):355–361. doi:10.1016/S1359-6462(97)00093-6
52.
SatoYS, KokawaH, EnomotoM, . Microstructural evolution of 6063 aluminum during friction-stir welding. Metall Mater Trans A. 1999;30:2429–2437. doi:10.1007/s11661-999-0251-1
53.
ReimannM, GartnerT, SuhuddinU, . Keyhole closure using friction spot welding in aluminum alloy 6061–T6. J Mater Process Technol. 2016;237:12–18. doi:10.1016/j.jmatprotec.2016.05.013
54.
AbioyeT, ZuhailawatiH, AnasyidaAS, . Investigation of the microstructure, mechanical and wear properties of AA6061-T6 friction stir weldments with different particulate reinforcements addition. J Mater Res Technol. 2019;8(5):3917–3928. doi:10.1016/j.jmrt.2019.06.055
YanS, ChenL, YobA, . Multifunctional metal matrix composites by friction stir additive manufacturing. J Mater Eng Perform. 2022;31(8):6183–6195. doi:10.1007/s11665-022-07114-7
57.
KumarPV, ReddyGM, RaoKS.Microstructure and pitting corrosion of armor grade AA7075 aluminum alloy friction stir weld nugget zone–effect of post weld heat treatment and addition of boron carbide. Def Technol. 2015;11(2):166–173. doi:10.1016/j.dt.2015.01.002
58.
SynC, LesuerD, SherbyO.Enhancing tensile ductility of a particulate-reinforced aluminum metal matrix composite by lamination with Mg-9% Li alloy. Mater Sci Eng A. 1996;206(2):201–207. doi:10.1016/0921-5093(95)09995-6
