Abstract
Friction stir processing (FSP) is a solid-state processing method, which recently gained wide popularity to modify the microstructure of metallic surfaces and to produce surface composites. For the past decade, composites of different materials such as aluminum, copper, magnesium, titanium, and their alloys were successfully produced by FSP. The amount of secondary phase that is dispersed at the surface of the workpiece during FSP and the level of dispersion depend on many factors such as tool design, processing parameters, and type of material. Recently, the method of secondary phase incorporation into the surface metals was also considered as an important factor in developing surface composites by FSP. A few strategies such as groove filling, holes filling, sandwich method, direct method, and surface coating followed by FSP methods have been developed as promising ways of secondary phase incorporation into the surface of the materials during FSP. The aim of this review paper is to give a comprehensive summary of different methods developed to disperse the secondary phase into the surface of the workpiece during FSP to produce surface composites. The strategies have been explained, compared, and discussed to suggest an appropriate method based on the requirement to adopt in developing surface composites.
Highlights
Friction stir processing (FSP) is a solid phase processing technique, developed to alter the microstructure of metallic sheets without melting the material and by inducing intense plastic deformation with the help of a rotating non-consumable tool that contains a pin at the end (Mishra and Ma 2005)
Along with the other influencing factors such as tool design and processing parameters, method of secondary phase incorporation is found to have a major role in distributing the powder particles and producing a successful composite (Gandra et al 2011; Miranda et al 2013)
It has been well demonstrated that FSP has a great potential in developing metallic surface composites in solid state itself
Summary
Friction stir processing (FSP) is a solid phase processing technique, developed to alter the microstructure of metallic sheets without melting the material and by inducing intense plastic deformation with the help of a rotating non-consumable tool that contains a pin at the end (Mishra and Ma 2005). FSP has been widely used to produce different metallic surface composites. B. International Journal of Mechanical and Materials Engineering (2016) 11:12 et al 2014b; Farnoush, Sadeghi, et al 2013; Farnoush, Bastami, et al 2013), and graphite (Soleymani et al 2012) are the widely used dispersing phases in producing surface composites using FSP. The objective of the present review is to give a comprehensive summary of different methods developed to incorporate secondary phase into the surface of the material in developing composites using FSP with an emphasis given to compare and discuss the methods
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