Friction Stir Welding and Processing
Fundamentals to Advancements
1st Edition
Published on 11. March 2024
Book
Hardback
352 pages
978-1-394-16943-6 (ISBN)
Description
Friction Stir Welding and Processing: Fundamentals to Advancements provides concise yet comprehensive coverage of the field of friction stir welding, with an eye toward future research directions and applications. After explaining the basic concepts and fundamentals of friction stir welding (FSW) and its variants and discussing composite fabrication techniques using Friction Stir Processing (FSP), the book delves into different types of friction techniques, including forming and extrusion, riveting, surface, and cladding, as well as the equipment used for FSW/FSP, microstructural characterization and mechanical testing of FSW/ FSP samples, and potential defects in FSW/FSP composites. Additional topics discussed include the impact of FSW on the economics of production, methods for coupling FSW/FSP with additive manufacturing, composite fabrication, process-property relationships. Case studies throughout the book provide real-world context and highlight applications for various engineering sectors. With contributions from an array of leaders in the field, Friction Stir Welding and Processing provides readers with a single source of information on all aspects of FSW and FSP.
More details
Language
English
Place of publication
New York
United States
Target group
Professional and scholarly
Dimensions
Height: 254 mm
Width: 178 mm
Thickness: 21 mm
Weight
830 gr
ISBN-13
978-1-394-16943-6 (9781394169436)
Copyright in bibliographic data and cover images is held by Nielsen Book Services Limited or by the publishers or by their respective licensors: all rights reserved.
Schweitzer Classification
Other editions
Additional editions
Sandeep Rathee | Manu Srivastava | J. Paulo Davim
Friction Stir Welding and Processing
Fundamentals to Advancements
E-Book
03/2024
1st Edition
Wiley
€115.99
Available for download
Persons
Sandeep Rathee, Ph.D. is an Assistant Professor in the Department of Mechanical Engineering at the National Institute of Technology, Srinagar, India. His research interests include friction stir welding/processing, additive manufacturing, composites, and hybrid manufacturing. He has previously co-authored three books on additive manufacturing.
Manu Srivastava, Ph.D. is an Assistant Professor in the Department of Mechanical Engineering at the Indian Institute of Technology, Jaipur. Her research interests include additive manufacturing, friction-based AM, friction stir processing, advanced materials, manufacturing practices and optimization techniques. She has previously co-authored two books on additive manufacturing.
J. Paulo Davim, Ph.D. is Professor at the University of Aviero, Portugal and a Fellow (FIET) of the Institution of Engineering and Technology, UK. His research interests include advanced manufacturing methods and materials and has authored and co-authors numerous books in these fields.
Manu Srivastava, Ph.D. is an Assistant Professor in the Department of Mechanical Engineering at the Indian Institute of Technology, Jaipur. Her research interests include additive manufacturing, friction-based AM, friction stir processing, advanced materials, manufacturing practices and optimization techniques. She has previously co-authored two books on additive manufacturing.
J. Paulo Davim, Ph.D. is Professor at the University of Aviero, Portugal and a Fellow (FIET) of the Institution of Engineering and Technology, UK. His research interests include advanced manufacturing methods and materials and has authored and co-authors numerous books in these fields.
Content
Preface xx
Acknowledgements xx
About the Editors xx
List of Contributors xx
List of Figures xx
List of Tables xiii
Chapter 1: Introduction to Friction Stir Welding
Farooz Najar Ahmad, Shazman Nabi, Sandeep Rathee, Manu Srivastava
1.1 Introduction
1.2 FSW setup and working principle
1.3 Weld Zones
1.4 Variants of FSW
1.5 Defects
1.6 Advantages and limitations of FSW
1.7 Conclusion and future prospectus
Chapter 2: Friction Stir Welding and Single Point Incremental Forming: State-of-the-Art
H. D. Mhatre, A. S. Mulay, V. S. Gadakh
2.1 Introduction
2.2 Friction stir welding (FSW)
2.3 Single Point Incremental Forming (SPIF):
2.4 FSW and SPIF
2.5 Summary and outlook
Chapter 3: Friction stir brazing and friction stir vibration brazing
Behrouz Bagheri, Mahmoud Abbasi
3.1 Introduction to FSB
3.2 Variants of FSB
3.3 Two Case studies
3.4 Application of FSB and its variants in industry
3.5 Summary and future directions
Chapter 4: Fundamentals of Friction Stir Processing
Atul Kumara, Devasri Fuloriaa, Manu Srivastava, Sandeep Rathee
4.1 Friction stir processing (FSP): Background
4.2 Working principle of FSP
4.3 Comparison with other SPD techniques
4.4 Process variables
4.5 Mechanisms of microstructural evolution during FSP
4.6 Critical issues in FSP
4.7 Future scope
Chapter 5: Role of FSP in surface engineering
Setu Suman, Kazi Sabiruddin
5.1 Introduction
5.2 Role of Surface Modification Techniques
5.3 Thermal Spray Technique
5.4. FSP - Solid State Coating Process
5.5 Process parameters of FSP: Surface engineering
5.6 Inappropriate characteristics of surface modification
5.7 Summary
Chapter 6: Surface composite fabrication using FSP
Baidehish Sahoo, Jinu Paul, and Abhishek Sharma
6.1 Introduction
6.2 Reinforcement incorporation approaches
6.3 Effect of process parameters
6.4 Microstructural evolution & mechanical properties
6.5 Strengthening mechanisms
6.6 Defects
6.7 Summary and Future directions
Chapter 7: Friction-stir welding of dissimilar metals
N. S. Khemnar, Y. R. Gunjal, V. S. Gadakh, A. S. Mulay
7.1 Introduction
7.2 Application areas of dissimilar material joining
7.3 Issues for dissimilar material joining
7.4 FSW of dissimilar materials
7.5 Recent developments in tool design and tool materials
7.6 Parameter Optimization
7.7 Common Defects occur in FSW of dissimilar metal joining
7.8 Future Recommendations for dissimilar metal joining
Chapter 8: Friction stir welding of aluminium and its alloys
P.Sivaprakasam, K.Deepak, D. Raja Joseph, Melaku Desta, Putti Venkata Siva Teja, M. Srinivasan
8.1 Introduction
8.2 Fundamentals of FSW
8.3 FSW of Aluminum and its alloy
8.4 Influences of process parameters
8.5 Testing and characterization of FSW of Al and its alloy
8.6 Additive mixed Friction Stir process of Al and its alloy
8.7 Applications
8.8 Conclusions
Chapter 9: Mechanical characterization of FSWed joints of dissimilar aluminum alloys of AA7050 and AA6082
Mohd Sajid, Gaurav Kumar, Husain Mehdi, Mukesh Kumar
9.1 Introduction
9.2 Materials and methods
9.3 Results and discussion
9.4 Conclusions
Chapter 10: Sample Preparation and Microstructural Characterization of Friction Stir Processed Surface Composites
Manu Srivastava, Sandeep Rathee, Shazman Nabi, Atul Kumar
10.1 Introduction
10.2 Sample preparation for microscopic analysis of metals, alloys and composites
10.3 Etching
10.4 Microstructural evolution
10.5 Conclusions
Chapter 11: Microstructural characterization and mechanical testing of FSWed/ FSPed samples
Prem Sagar, Sushma, M. Ashok kumar
11.1 Introduction
11.2 Microstructural characterization
11.3 Mechanical Testing
11.4 Conclusions
Chapter 12: Comparative Analysis of Microstructural and Mechanical Characteristics of Reinforced FSW Welds
Tanvir Singh
12.1 Introduction
12.2 Friction Stir Welding (FSW)
12.3 Reinforcing materials-based Fabrication of FSW Welds
12.4 Joinability of reinforced FSW welds
12.5 Metallurgical characteristics of FSW reinforced welds
12.6 Mechanical behavior of reinforced FSW welds
12.7 Conclusions
12.8 Future challenges
Chapter 13: Summary of efforts in manufacturing of sandwich sheets by various joining methods including solid-state joining method
Divya Sachan , R. Ganesh Narayanan and Arshad Noor Siddiquee
13.1 Introduction
13.2 Sandwich sheets
13.3 Classification of Sandwich sheet structures
13.4 Applications
13.5 Fabrication methods
13.6 Summary
Chapter 14: Defects in Friction Stir Welding and its Variant Processes
Vinayak Malik and Satish V. Kailas
14.1 Introduction
14.2 General Defects in FSW
14.3 Characteristic Defects in Friction Stir Butt and Lap Joints
14.4 Distinctive Defects in Major Friction Stir Variants
14.5 Solutions to avoid defects in Friction Stir based processes
14.6 Summary and concluding remarks
Chapter 15: Nondestructive ultrasonic inspections, evaluations, and monitoring in FSW / FSP
Yuqi Jin, Teng Yang, Narendra B. Dahotre, and Tianhao Wang
1. Ultrasonic wave behaviors in FSWed/FSPed samples
1.1. Influence from defects on ultrasound wave travelling
1.2. Influence from microstructures on ultrasound wave travelling
1.3. Influence from residual stresses on ultrasound wave travelling
2. Current ultrasonic inspection and evaluation methods for FSWed/FSPed samples
2.1. Ultrasound inspections on defects and flaws for FSWed/FSPed samples
2.2. Ultrasound evaluations on mechanical properties for FSWed/FSPed samples
2.3. Ultrasound monitoring for FSW/FSP
3. Case studies on recent novel ultrasound evaluation and monitoring in FSW / FSP
3.1. Ultrasonic elastographic evaluated dissimilar FSWed samples
3.2. Ultrasonic elastographic evaluated FSPed sample
3.3. Ultrasonic effective residual stress mapping on FSPed sample
3.4. Ultrasonic monitoring on FSW/FSP tool wearing
4. Roles and potentials of ultrasound in future FSW / FSP
Chapter 16: Applications of Friction Stir Welding
Raja Gunasekaran, Gobinath Velu Kaliyannan, K. Suganeswaran, N. Nithyavathy, S. Arun Kumar
16.1 Introduction
16.2 Application of FSW on Different Materials
16.3 Industrial applications of FSW
16.4 Conclusions
Chapter 17: Equipment used during FSP
Suganeswaran K, Nithyavathy N, Muthukumar P, Arunkumar S, Gobinath V. K
17.1 Introduction
17.2 FSP experimental setup
17.3 Microstructural characterization
17.4 Mechanical behaviour of composites based on various tool shapes
17.5 Mechanical behaviour of composites based on various process parameters
17.6 Conclusions
Chapter 18: Analysis of Friction Stir Welding Tool Using Various Threaded Pin Profiles: A Case Study
Bommana Boina Abhignya, Ashish Yadav, Manu Srivastava, Sandeep Rathee
18.1 Introduction
18.2 Geometry Considered
18.3 Results and Discussions - Analysis in ANSYS
18.4 Conclusion
References
Chapter 19: Static Structural and Thermal Analysis of Honeycomb Structure Fabricated by Friction Stir Process Route: A Case Study
Nikhil Jaiswal, Umashankar Bharti , Ashish Yadav, Manu Srivastava, Dr Sandeep Rathee
19.1. Introduction
19.2. Modelling
19.3. Result and Analysis
19.4. Scope of the study
19.5. Conclusion
Chapter 20: Friction Stir-based Additive Manufacturing
A. Gourav Rao and Neelam Meena
20.1 Additive Manufacturing: An Introduction
20.2 Solid-State AM processes
20.3 Case studies of FSAM on different materials
20.4 Advantages of FSAM over other AM techniques
20.5 Advancements
20.6 Limitations
20.7 Conclusions & Future prospectives
References
Acknowledgements xx
About the Editors xx
List of Contributors xx
List of Figures xx
List of Tables xiii
Chapter 1: Introduction to Friction Stir Welding
Farooz Najar Ahmad, Shazman Nabi, Sandeep Rathee, Manu Srivastava
1.1 Introduction
1.2 FSW setup and working principle
1.3 Weld Zones
1.4 Variants of FSW
1.5 Defects
1.6 Advantages and limitations of FSW
1.7 Conclusion and future prospectus
Chapter 2: Friction Stir Welding and Single Point Incremental Forming: State-of-the-Art
H. D. Mhatre, A. S. Mulay, V. S. Gadakh
2.1 Introduction
2.2 Friction stir welding (FSW)
2.3 Single Point Incremental Forming (SPIF):
2.4 FSW and SPIF
2.5 Summary and outlook
Chapter 3: Friction stir brazing and friction stir vibration brazing
Behrouz Bagheri, Mahmoud Abbasi
3.1 Introduction to FSB
3.2 Variants of FSB
3.3 Two Case studies
3.4 Application of FSB and its variants in industry
3.5 Summary and future directions
Chapter 4: Fundamentals of Friction Stir Processing
Atul Kumara, Devasri Fuloriaa, Manu Srivastava, Sandeep Rathee
4.1 Friction stir processing (FSP): Background
4.2 Working principle of FSP
4.3 Comparison with other SPD techniques
4.4 Process variables
4.5 Mechanisms of microstructural evolution during FSP
4.6 Critical issues in FSP
4.7 Future scope
Chapter 5: Role of FSP in surface engineering
Setu Suman, Kazi Sabiruddin
5.1 Introduction
5.2 Role of Surface Modification Techniques
5.3 Thermal Spray Technique
5.4. FSP - Solid State Coating Process
5.5 Process parameters of FSP: Surface engineering
5.6 Inappropriate characteristics of surface modification
5.7 Summary
Chapter 6: Surface composite fabrication using FSP
Baidehish Sahoo, Jinu Paul, and Abhishek Sharma
6.1 Introduction
6.2 Reinforcement incorporation approaches
6.3 Effect of process parameters
6.4 Microstructural evolution & mechanical properties
6.5 Strengthening mechanisms
6.6 Defects
6.7 Summary and Future directions
Chapter 7: Friction-stir welding of dissimilar metals
N. S. Khemnar, Y. R. Gunjal, V. S. Gadakh, A. S. Mulay
7.1 Introduction
7.2 Application areas of dissimilar material joining
7.3 Issues for dissimilar material joining
7.4 FSW of dissimilar materials
7.5 Recent developments in tool design and tool materials
7.6 Parameter Optimization
7.7 Common Defects occur in FSW of dissimilar metal joining
7.8 Future Recommendations for dissimilar metal joining
Chapter 8: Friction stir welding of aluminium and its alloys
P.Sivaprakasam, K.Deepak, D. Raja Joseph, Melaku Desta, Putti Venkata Siva Teja, M. Srinivasan
8.1 Introduction
8.2 Fundamentals of FSW
8.3 FSW of Aluminum and its alloy
8.4 Influences of process parameters
8.5 Testing and characterization of FSW of Al and its alloy
8.6 Additive mixed Friction Stir process of Al and its alloy
8.7 Applications
8.8 Conclusions
Chapter 9: Mechanical characterization of FSWed joints of dissimilar aluminum alloys of AA7050 and AA6082
Mohd Sajid, Gaurav Kumar, Husain Mehdi, Mukesh Kumar
9.1 Introduction
9.2 Materials and methods
9.3 Results and discussion
9.4 Conclusions
Chapter 10: Sample Preparation and Microstructural Characterization of Friction Stir Processed Surface Composites
Manu Srivastava, Sandeep Rathee, Shazman Nabi, Atul Kumar
10.1 Introduction
10.2 Sample preparation for microscopic analysis of metals, alloys and composites
10.3 Etching
10.4 Microstructural evolution
10.5 Conclusions
Chapter 11: Microstructural characterization and mechanical testing of FSWed/ FSPed samples
Prem Sagar, Sushma, M. Ashok kumar
11.1 Introduction
11.2 Microstructural characterization
11.3 Mechanical Testing
11.4 Conclusions
Chapter 12: Comparative Analysis of Microstructural and Mechanical Characteristics of Reinforced FSW Welds
Tanvir Singh
12.1 Introduction
12.2 Friction Stir Welding (FSW)
12.3 Reinforcing materials-based Fabrication of FSW Welds
12.4 Joinability of reinforced FSW welds
12.5 Metallurgical characteristics of FSW reinforced welds
12.6 Mechanical behavior of reinforced FSW welds
12.7 Conclusions
12.8 Future challenges
Chapter 13: Summary of efforts in manufacturing of sandwich sheets by various joining methods including solid-state joining method
Divya Sachan , R. Ganesh Narayanan and Arshad Noor Siddiquee
13.1 Introduction
13.2 Sandwich sheets
13.3 Classification of Sandwich sheet structures
13.4 Applications
13.5 Fabrication methods
13.6 Summary
Chapter 14: Defects in Friction Stir Welding and its Variant Processes
Vinayak Malik and Satish V. Kailas
14.1 Introduction
14.2 General Defects in FSW
14.3 Characteristic Defects in Friction Stir Butt and Lap Joints
14.4 Distinctive Defects in Major Friction Stir Variants
14.5 Solutions to avoid defects in Friction Stir based processes
14.6 Summary and concluding remarks
Chapter 15: Nondestructive ultrasonic inspections, evaluations, and monitoring in FSW / FSP
Yuqi Jin, Teng Yang, Narendra B. Dahotre, and Tianhao Wang
1. Ultrasonic wave behaviors in FSWed/FSPed samples
1.1. Influence from defects on ultrasound wave travelling
1.2. Influence from microstructures on ultrasound wave travelling
1.3. Influence from residual stresses on ultrasound wave travelling
2. Current ultrasonic inspection and evaluation methods for FSWed/FSPed samples
2.1. Ultrasound inspections on defects and flaws for FSWed/FSPed samples
2.2. Ultrasound evaluations on mechanical properties for FSWed/FSPed samples
2.3. Ultrasound monitoring for FSW/FSP
3. Case studies on recent novel ultrasound evaluation and monitoring in FSW / FSP
3.1. Ultrasonic elastographic evaluated dissimilar FSWed samples
3.2. Ultrasonic elastographic evaluated FSPed sample
3.3. Ultrasonic effective residual stress mapping on FSPed sample
3.4. Ultrasonic monitoring on FSW/FSP tool wearing
4. Roles and potentials of ultrasound in future FSW / FSP
Chapter 16: Applications of Friction Stir Welding
Raja Gunasekaran, Gobinath Velu Kaliyannan, K. Suganeswaran, N. Nithyavathy, S. Arun Kumar
16.1 Introduction
16.2 Application of FSW on Different Materials
16.3 Industrial applications of FSW
16.4 Conclusions
Chapter 17: Equipment used during FSP
Suganeswaran K, Nithyavathy N, Muthukumar P, Arunkumar S, Gobinath V. K
17.1 Introduction
17.2 FSP experimental setup
17.3 Microstructural characterization
17.4 Mechanical behaviour of composites based on various tool shapes
17.5 Mechanical behaviour of composites based on various process parameters
17.6 Conclusions
Chapter 18: Analysis of Friction Stir Welding Tool Using Various Threaded Pin Profiles: A Case Study
Bommana Boina Abhignya, Ashish Yadav, Manu Srivastava, Sandeep Rathee
18.1 Introduction
18.2 Geometry Considered
18.3 Results and Discussions - Analysis in ANSYS
18.4 Conclusion
References
Chapter 19: Static Structural and Thermal Analysis of Honeycomb Structure Fabricated by Friction Stir Process Route: A Case Study
Nikhil Jaiswal, Umashankar Bharti , Ashish Yadav, Manu Srivastava, Dr Sandeep Rathee
19.1. Introduction
19.2. Modelling
19.3. Result and Analysis
19.4. Scope of the study
19.5. Conclusion
Chapter 20: Friction Stir-based Additive Manufacturing
A. Gourav Rao and Neelam Meena
20.1 Additive Manufacturing: An Introduction
20.2 Solid-State AM processes
20.3 Case studies of FSAM on different materials
20.4 Advantages of FSAM over other AM techniques
20.5 Advancements
20.6 Limitations
20.7 Conclusions & Future prospectives
References