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Material analysis of friction stir forming and friction stir deposition

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Item Summary

Title: Material analysis of friction stir forming and friction stir deposition
Authors: Ogata, Kenneth A.
Keywords: Friction
Issue Date: Dec 2013
Publisher: [Honolulu] : [University of Hawaii at Manoa], [December 2013]
Abstract: Friction stir forming (FSF) can be utilized to join dissimilar materials without the added weight of nuts, bolts, rivets, etc. This process uses friction to heat and form metal, in order to join two materials together. This process can have many applications from automotive, and aerospace where new dissimilar materials are being used in order to reduce weight and improve strength. The FSF process will be studied to better understand how the material behaves when it is being deformed. Friction stir deposition (FSD) is being studied primarily for its use in the naval industry. Monel is used for its anti-corrosion abilities on the hulls of ships. The current electro-deposition process is cumbersome and requires the surface to be cleaned and prepared before hand. It is believed that with the simple FSD process, monel can be effectively deposited on the hull of a ship. The process will be studied to find the effect of different process parameters on deposition quality. Research will also be done on deposition of aluminum on steel, and depositing aluminum in a crack using FSD.
Both FSF and FSD show potential as efficient and effective processes. The FSF process was examined at different depths, which were also linked to the force and torque. The FSF process appeared to create two layers within the aluminum. The top layer that rotated along with the tool, and the bottom layer that did not rotate and was formed into the cavity. The shape of the formed material was also interesting. The direction of flow did not correlate with the direction of rotation. Instead, material seemed to be pushed from area of higher forming to area of less forming. The area with highest forming was midway between the center and edge of the tool. This arc showed an approximate radial symmetry around the tool.
We were able to deposit both monel and aluminum on steel. 6061 Al was relatively easy to deposit compared to the harder monel. The monel surface was up to 100 um thick when viewed under SEM. Depositing the aluminum in cracks was also done with 6061 Al. This process proved possible for cracks 3.0 and 0.5 mm wide.
Description: M.S. University of Hawaii at Manoa 2013.
Includes bibliographical references.
Appears in Collections:M.S. - Mechanical Engineering

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