Friction stir welding

FSW of Aluminum with PP : Joining different parts is one of the crucial components of designing/engineering of materials. Presently, the current energy efficient low weight automotive and aerospace components consist of a different class of materials, such as metals, polymers, ceramics, etc. Joining these components remains a challenge. Here, we demonstrate metal (aluminum) and polymer (Polypropylene, pp) joining using mechanical friction. The detailed characterization clearly demonstrates that atomically locked interfaces are formed in such joining and no chemical bonds are formed during the joining.

Modeling and simulation

Modeling of Dissimilar FSW: A heat transfer numerical model is developed for friction stir welding of dissimilar materials Al 6061 and AZ31 alloy. Thermophysical properties were experimentally determined for the stir zone and compared with the base alloys. Experimentally determined thermo-physical properties of the stir zone are not strictly the average values of the base alloys but exhibit a complex relationship with the microstructural features and the intermixing of Al and Mg in the weld region.

Surface composites

Friction stir processing (FSP) is a suitable solid state processing route for surface composite preparation. Solid state processing route is superior in terms of compatibility and energy efficiency compared to conventional liquid state processing methods. The FSP, derived from the friction stir welding (FSW) process, is carried out at temperatures lower than the melting temperature of the base alloy. The surface composite preparation through FSP imparts minimal thermal effect on the processed material.

Friction stir channeling

The Friction stir channelling (FSC) process is based on the concept of transforming the void or tunnel defect originating in advancing side of Friction Stir process into continuous integral channel. The process was first invented and patented as manufacturing technique for heat exchanging devices and can have wide range application in compact heat exchanger industries. The important aspect for use of the channel in any thermal application is thermo-hydraulic performance. The geometrical parameters of channel (Shape, Cross Sectional Area, Surface Area, hydraulic diameter, Surface Roughness, and Length) decide the thermo-hydraulic performance of channel.

Additive Manufacuring

Additive manufacturing of titanium alloy Ti-6Al-4 V has significantly increased over the past few years, primarily due to its broad application over the conventional manufacturing process for complex and near net shape production. However, difficulties arise while printing complex and huge structures and therefore, the components need a suitable joining process. We study the feasibility of friction stir welding of Ti-6Al-4 V plates made by electron beam melting, performing both microstructural and mechanical analysis.