Research Methodologies that can be used for surface modifications of non-ferrous alloys in Friction Stir Processing – A Review
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Abstract
Friction Stir Processing (FSP) is an innovative solid-state processing technique that holds significant promise for the enhancement of non-ferrous alloys, particularly aluminum and magnesium. Unlike traditional methods involving melting and casting, FSP operates at temperatures below the material's melting point, preserving its inherent properties and mitigating defects associated with liquid-state processing. The technique employs a non-consumable, specially designed tool with a rotating pin and shoulder, which is plunged into the material and traversed along the surface. This action generates intense frictional heat, leading to plastic deformation and subsequent recrystallization. In non-ferrous alloys, FSP results in refined microstructures, improved mechanical properties, and enhanced wear resistance. The process has found widespread applications in aerospace, automotive, and other industries where lightweight and high-performance materials are crucial. Various approaches like numerical modelling, taguchi and analytical modelling can be followed while processing for optimization of processing parameters. The microstructural modifications induced by FSP contribute to grain refinement, reducing porosity and enhancing the overall integrity of the material. Furthermore, FSP enables the incorporation of reinforcing particles, leading to the formation of surface composites with tailored properties.