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Lubricants
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Friction Stir Processing of Structural Metallic Materials
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Friction Stir Processing of Structural Metallic Materials

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (1 February 2024) | Viewed by 15098

Special Issue Editors

Dr. Anna Zykova

E-Mail Website
Guest Editor
Institute of Strength Physics and Materials Science, Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
Interests: friction stir processing; structural metallic materials; mechanical properties; microstructure; phase transformation; recrystallisation; composite material
Prof. Dr. Sergei Tarasov

E-Mail Website
Guest Editor
Institute of Strength Physics and Materials Science of Siberian Branch Russian Academy of Sciences (ISPMS SB RAS), 2/4, pr. Akademicheskii, 634055 Tomsk, Russia
Interests: tribology; materials science; solid state physics
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In the last decade, friction stir processing has attracted a significant amount of interest and shown substantial advances in the production of graded structures in the surface layers of metallic structural materials. Such graded structures can be formed using friction stir processing, which allows for the combining of different structure modification factors, such as the formation of nanoscale grains and the structural homogeneity of materials in the surface layer; the modification and hardening of the material surface by dispersed particles of different chemical compositions; and the fabrication of hybrid as well as in situ compounds. However, there are still open issues connected with the selection of technological parameters of FSP for processing structural material, including the effect of FSP tool configuration on the transfer of plasticized material and structural phase composition during FSP; the effect of intermixing with powders of different chemical compositions; the secondary phase precipitation selection of tool material for processing titanium alloys, nickel superalloys, and high-entropy alloys; study of friction processes; and others. We invite all FSP specialists to publish articles and reviews on the following topics:

  • The effect of technological parameters and tool configurations on the formation of structural phase composition, mechanical properties, tribological properties, and corrosion properties of aluminum, copper, titanium, magnesium alloys, nickel superalloys, and steels;

  • Effect of additives (ultradispersed powders of metals, nitrides, carbides, oxides, and nanocarbon materials) on the formation of structural phase compositions, mechanical properties, tribological properties, and corrosion properties of aluminum, copper, titanium, magnesium alloys, nickel superalloys, and steels;
  • Modeling/simulation of processes during FSP of aluminum, copper, titanium, magnesium alloys, nickel superalloys, and steels;
  • Development of tool material for processing titanium alloys, nickel superalloys, and high-entropy alloys;
  • Study of FSP tool wear interaction with aluminum, copper, titanium, magnesium alloys, nickel superalloys, and steels;
  • Study of friction processes, FSP tool wear, and material flow transfer mechanisms during FSP;
  • Research on biological properties and the development of special medical materials.

The current Special Issue aims to bring together the work of the world's leading scientists working in the field of FSP of materials in order to enhance the understanding of the processes occurring in FSP and to produce materials with improved mechanical and functional characteristics, including medical prescribing.

Dr. Anna Zykova
Prof. Dr. Sergei Tarasov
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • friction stir processing
  • structural metallic materials
  • mechanical properties
  • microstructure evolution
  • phase composition
  • tribocorrosion
  • corrosion
  • tribometry
  • modelling/simulation of friction stir processing
  • lubricants
  • wear mechanisms
  • biological properties
  • medical prescribing

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Published Papers (8 papers)

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Research

16 pages, 3962 KiB  
Article
A Comprehensive Investigation of BN and VC Reinforcements on the Properties of FSP AA6061 Composites
by Essam B. Moustafa, Fathi Djouider, Abdulsalam Alhawsawi, Ezzat Elmoujarkach, Essam Banoqitah and Samah S. Mohamed
Lubricants 2023, 11(12), 507; https://doi.org/10.3390/lubricants11120507 - 30 Nov 2023
Cited by 4 | Viewed by 1524
Abstract
This present study investigated the impact of incorporating boron nitride (BN) and vanadium carbide (VC) reinforcements on various properties of friction stir processed (FSP) AA6061 alloy composites, focusing specifically on grain structure, thermal conductivity, electrical conductivity, and compressive strength. The findings indicate that [...] Read more.
This present study investigated the impact of incorporating boron nitride (BN) and vanadium carbide (VC) reinforcements on various properties of friction stir processed (FSP) AA6061 alloy composites, focusing specifically on grain structure, thermal conductivity, electrical conductivity, and compressive strength. The findings indicate that VC more effectively refines the grain structure of the AA6061 alloy during FSP compared to BN. The inclusion of BN particles in the metal matrix composites resulted in a decrease in both thermal and electrical conductivity. In contrast, the addition of VC particles led to an increase in both thermal and electrical conductivity. The AA6061/VC composite material exhibited the highest thermal conductivity among all composites tested. The electrical conductivity of the hybrid-composite AA6061/30%BN+70%VC showed a slight reduction, measuring only 2.8% lower than the base alloy AA6061. The mono-composite AA6061/VC exhibited a marginal decrease in thermal conductivity, with a measured value only 7.5% lower than the conventional alloy AA6061. However, the mono-composite AA6061/BN displayed a more significant decline, exhibiting a loss of 14.7% and 13.9% in electrical and thermal conductivity, respectively. The composite material comprising 30% BN and 70% VC reinforcement demonstrated the highest compressive strength compared to all other tested composites. The observed percentage enhancement in the mechanical properties of mono and hybrid composites, compared to the parent AA6061 alloy, ranged from 17.1% to 31.5%. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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20 pages, 19159 KiB  
Article
Wear of Ni-Based Superalloy Tools in Friction Stir Processing of Commercially Pure Titanium
by Alihan Amirov, Alexander Eliseev and Vladimir Beloborodov
Lubricants 2023, 11(7), 307; https://doi.org/10.3390/lubricants11070307 - 21 Jul 2023
Cited by 3 | Viewed by 1120
Abstract
Conventional methods for joining titanium alloys often provide a relatively low quality of joints impaired by high residual stresses. A possible solution to this problem can be offered by friction stir welding, which has been increasingly used for aluminum alloys. However, the friction [...] Read more.
Conventional methods for joining titanium alloys often provide a relatively low quality of joints impaired by high residual stresses. A possible solution to this problem can be offered by friction stir welding, which has been increasingly used for aluminum alloys. However, the friction stir welding of titanium alloys is complicated by severe tool wear due to high loads and temperatures in the process. Good results were reported for a tool made of ZhS6U superalloy, but tool life still needs to be improved. Here, we study the wear of a tool made of ZhS32 Ni-based superalloy, which has higher heat resistance than ZhS6U, and the wear of a liquid-cooled ZhS6U tool in the friction stir processing of commercially pure titanium. The effect of tool wear on the strength characteristics of the processed material is discussed. The total processing path length traversed by the tools without failure was 2790 mm. In both cases, the most severe wear was observed at the pin root. Liquid cooling significantly reduced the wear. Based on the obtained results, tool wear is proposed to occur by an adhesion–diffusion mechanism during friction stir processing. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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15 pages, 9630 KiB  
Article
Effects of Tool Plunging Path on the Welded Joint Properties of Pinless Friction Stir Spot Welding
by Xiaole Ge, Di Jiang, Weiwei Song and Hongfeng Wang
Lubricants 2023, 11(3), 150; https://doi.org/10.3390/lubricants11030150 - 21 Mar 2023
Cited by 1 | Viewed by 1394
Abstract
Four tool plunging paths including a one-time plunging path and three step-by-step plunging paths were designed to study the effects of the tool plunging path on the welded joint properties of pinless friction stir spot welding (PFSSW). The appearance, cross-sectional microstructure, welding temperature, [...] Read more.
Four tool plunging paths including a one-time plunging path and three step-by-step plunging paths were designed to study the effects of the tool plunging path on the welded joint properties of pinless friction stir spot welding (PFSSW). The appearance, cross-sectional microstructure, welding temperature, microhardness, and tensile shear failure load of the PFSSW of thin copper sheets under different tool plunging paths were explored. Furthermore, the fracture modes of welded joints under different tool plunging paths were analyzed. Studies showed that path 1 (plunge total depth at one time) produced the largest range of stirring zone, but the grains in the stirring zone were larger and the width of the thermal-mechanical affected zone was smaller. Path 1 obtained the highest peak temperature during the welding process, and path 3 (plunge 1/3 total depth + plunge 2/3 total depth) gained the lowest peak temperature. The greater the initial plunging amount of the tool, the faster the temperature rise rate in the welding stage. The tensile shear failure loads for path 1, path 2 (plunge 1/2 total depth + plunge 1/2 total depth), path 3, and path 4 (plunge 2/3 total depth + plunge 1/3 total depth) were 8.65 kN, 8.15 kN, 8.25 kN, and 8.85 kN, respectively. The tensile shear failure load of path 4 was 2.3% higher than that of path 1. The fracture modes of welded joints under different tool plunging paths were all nugget pullout fractures. The fracture morphology indicated that the fracture type was ductile fracture. The step-by-step plunging path proposed in this work extends the traditional PFSSW process. The findings of this study can provide a reference for the selection and design of tool plunging paths for PFSSW. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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19 pages, 21819 KiB  
Article
Effect of Multi-Pass Friction Stir Processing on Microstructure and Mechanical Properties of a Metastable Dual-Phase High Entropy Alloy
by Neelam Meena, Ardula Gourav Rao, Satya Gowtam Dommeti and Nithyanand Prabhu
Lubricants 2023, 11(1), 2; https://doi.org/10.3390/lubricants11010002 - 20 Dec 2022
Cited by 7 | Viewed by 1852
Abstract
Studies on Multi-pass Friction Stir Processing (FSP) of Fe49.5Mn30Co10Cr10C0.5, a metastable dual-phase High Entropy Alloy (HEA), were carried out with the aim to systematically investigate the microstructural changes occurring during different passes, and to [...] Read more.
Studies on Multi-pass Friction Stir Processing (FSP) of Fe49.5Mn30Co10Cr10C0.5, a metastable dual-phase High Entropy Alloy (HEA), were carried out with the aim to systematically investigate the microstructural changes occurring during different passes, and to evaluate the mechanical response of this alloy with progressive passes. A reduction in grain size and a change in HCP volume fraction was observed after each pass. Dynamic recrystallization, occurring during FSP, led to grain refinement, and the transformation induced plasticity (TRIP) effect resulted in observed changes in HCP phase fraction. One-pass FSPed material exhibits a higher work hardening rate and a higher ultimate tensile strength (UTS.) value, as compared to both, an annealed and two-pass FSPed material. This is due to a combination of two factors, a small grain size and a large fraction of metastable Face Centred Cubic (FCC) phase, in the microstructure of the one-pass material. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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19 pages, 7004 KiB  
Article
Thermo-Mechanical Modelling of Friction Stir Processing of AZ91 Alloy: Using Smoothed-Particle Hydrodynamics
by Roshan Vijay Marode, Srinivasa Rao Pedapati, Tamiru Alemu Lemma and Venkata Somi Reddy Janga
Lubricants 2022, 10(12), 355; https://doi.org/10.3390/lubricants10120355 - 8 Dec 2022
Cited by 15 | Viewed by 1903
Abstract
A thermo-mechanical model of friction stir processing (FSP) using the Altair based on meshless Smoothed-Particle Hydrodynamics (SPH) was developed and verified experimentally. Process parameters adopted for both experimentation and simulation during the FSP of AZ91 were 1000 rpm tool stirring speed, 40 mm/min [...] Read more.
A thermo-mechanical model of friction stir processing (FSP) using the Altair based on meshless Smoothed-Particle Hydrodynamics (SPH) was developed and verified experimentally. Process parameters adopted for both experimentation and simulation during the FSP of AZ91 were 1000 rpm tool stirring speed, 40 mm/min tool advancing speed, and 0° tool tilt angle. The numerical analysis predicted the temperature distribution and material movement in the three phases: plunging, dwelling, and traversing. Simulated temperatures during the traversal phase were found to be greater than experimental temperatures using the Ti32 thermal camera as the heat was only transported by friction and plastic deformation. Peak temperatures for all three phases were observed to be in the range of 47% to 87% of the material’s melting point and are in accordance with the findings of the experiments. The SPH mesh-free model was proven to be capable of predicting the in-process thermal-mechanical state variables during and after the process by extracting morphology. The material movement around the tool has been predicted using SPH node tracking, which further anticipates that there was no complete flow of SPH nodes from RS to AS, leaving a gap that must be filled. Post-processed morphology shows inadequacy in the material flow due to lower compressive force. It formed the wormhole at the advancing side’s trailing and was verified experimentally. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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11 pages, 5702 KiB  
Article
Structural Changes in Block-Shaped WEBAM’ed Ti6Al4V Samples after Friction Stir Processing
by Tatiana Kalashnikova, Andrey Cheremnov, Aleksander Eliseev, Denis Gurianov, Evgeny Knyazhev, Evgeny Moskvichev, Vladimir Beloborodov, Andrey Chumaevskii, Anna Zykova and Kirill Kalashnikov
Lubricants 2022, 10(12), 349; https://doi.org/10.3390/lubricants10120349 - 4 Dec 2022
Cited by 2 | Viewed by 1733
Abstract
In this paper, the structure and mechanical properties of workpieces made of Ti6Al4V alloy in the shape of blocks manufactured by wire-feed electron beam additive manufacturing and processed by friction stir processing were investigated. Samples were cut from the upper and lower parts [...] Read more.
In this paper, the structure and mechanical properties of workpieces made of Ti6Al4V alloy in the shape of blocks manufactured by wire-feed electron beam additive manufacturing and processed by friction stir processing were investigated. Samples were cut from the upper and lower parts of the additive block and processed in the layer deposition direction using different tool loading forces. Studies have shown that the processing of such material forms a clearly defined thermomechanically affected zone represented by nanosized α-grains. In the stir zone, the material is characterized by a fine-dispersed structure with a content of α- and nanosized α″-phase plates. The material after processing demonstrates 24% higher values of the ultimate tensile strength as compared to the base metal in the as-built state. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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19 pages, 9834 KiB  
Article
Comparison of Machining Simulations of Aerospace Alloy Al6061-T6 Using Lagrangian and Smoothed Particle Hydrodynamics Techniques
by Muhammad N. Nawaz, Sohaib Z. Khan, Muhammad Asif, Abdulrahman Aljabri, Asad A. Zaidi and Essam R. I. Mahmoud
Lubricants 2022, 10(11), 310; https://doi.org/10.3390/lubricants10110310 - 15 Nov 2022
Cited by 1 | Viewed by 1900
Abstract
This research focuses on the study of the simulation capabilities of the lagrangian (LAG) model and Smoothed Particle Hydrodynamics (SPH) model for the orthogonal dry machining of aluminum alloy Al6061-T6. A three-dimensional finite element model was developed and verified using experimental data from [...] Read more.
This research focuses on the study of the simulation capabilities of the lagrangian (LAG) model and Smoothed Particle Hydrodynamics (SPH) model for the orthogonal dry machining of aluminum alloy Al6061-T6. A three-dimensional finite element model was developed and verified using experimental data from the published literature. The numerical models were developed using lagrangian boundary conditions via finite element modeling in ABAQUS/Explicit 6.14. The cutting simulations were carried out at low and medium cutting speeds. Johnson–Cook material constitutive law and Johnson–Cook damage law were used in both models. The numerical methodologies are compared based on cutting forces, chip morphology, shear angle, chip separation criterion, and chip thickness. The findings of the present work show that the LAG model is good for predictions regarding cutting forces and chip morphology, while the SPH model is good for predictions regarding the shear angle and chip thickness. The difference between results generated by both models mainly occurred due to the friction coefficient. The comparative study shown here offers a guidance approach for various numerical models for appropriate parameter analysis. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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24 pages, 27232 KiB  
Article
Wear Analysis of Friction Stir Processed AA7075-SiC-Graphite Hybrid Surface Composites
by Namdev Ashok Patil, Srinivasa Rao Pedapati and Roshan Vijay Marode
Lubricants 2022, 10(10), 267; https://doi.org/10.3390/lubricants10100267 - 18 Oct 2022
Cited by 14 | Viewed by 2336
Abstract
High specific strength and superior corrosion resistance are two key characteristics of the aerospace grade AA7075-T6 alloy. However, the surface behavior of AA7075-T6 is found to be deprived, because of its behavior of being prone to fretting fatigue and adhesive wear under dry [...] Read more.
High specific strength and superior corrosion resistance are two key characteristics of the aerospace grade AA7075-T6 alloy. However, the surface behavior of AA7075-T6 is found to be deprived, because of its behavior of being prone to fretting fatigue and adhesive wear under dry sliding conditions. Thus, surface wear behavior improvement with the retention of the microhardness of the alloy is required for increasing its wider application. For this, surface isomorphous precipitates and the soft matrix need to be protected through dispersion of hard thermally stable ceramic SiC with solid-lubricant graphite particles. The dispersion through friction stir processing (FSP) avoids detrimental phase formations by processing the metal alloy below its melting point temperature. Thus, dispersion of SiC-Graphite inside the AA7075-T6 using FSP is the focal point of the study. The low and high wear rate samples have been analyzed using SEM imaging and elemental analysis through XRD and EDS mapping. In this study, reinforcing the SiC-Gr particles greatly improved the wear behavior of the AA7075 alloy. Wear resistance has been controlled by combining soft solid lubricant Gr particles with load-bearing hard SiC nanoparticles. In dry sliding action, the base alloy matrix was severely exposed to wear, but the hard SiC nanoparticles served as load-bearing asperities and improved the wear resistance. Simultaneously, the graphite layers generated the soft solid lubricating tribofilm further to reduce the wear and friction between mating surfaces. The wear mechanisms have changed prominently from adhesion to abrasion and delamination through reinforcing the SiC-Gr reinforcements. The graphite content in a hybrid ratio with SiC hard particles was found to have improved the wear resistance by 78%. The tendency of fatigue was more effectively improved in surface composites as compared to the base alloy. Full article
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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