Article
Materials Science, Multidisciplinary
Nikhil Gotawala, Neeraj Kumar Mishra, Amber Shrivastava
Summary: The present study aims to analyze the microstructure and mechanical properties of multilayer SS304 deposited by friction stir metal deposition. Continuous dynamic recrystallization is found to be the main mechanism for grain refinement in the deposited region. The grains at the interface of deposited layers are significantly refined, and the twin boundary and martensite fractions are reduced in the bulk of the layers. However, strain-induced martensitic transformation is observed at the interface of the successively deposited regions due to lower initial temperatures.
Article
Materials Science, Multidisciplinary
Hang Z. Yu, Rajiv S. Mishra
Summary: Additive friction stir deposition, as a counterpart to fusion-based additive processes, offers a solid-state deformation processing route for metal additive manufacturing. Its key advantages include producing fully-dense material in the printed state with fine, equiaxed microstructures, making it suitable for industries requiring high load-bearing capacity with minimal post-processing.
MATERIALS RESEARCH LETTERS
(2021)
Review
Engineering, Mechanical
Smrity Choudhury, Uttam Acharya, Joydeep Roy, Barnik Saha Roy
Summary: This article provides an overview of the processes, materials, and process parameters of friction stir additive manufacturing (FSAM). Compared to traditional fusion-based additive manufacturing methods, FSAM can produce defect-free components with excellent mechanical and structural properties.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Chemistry, Physical
Hamed Ghadimi, Huan Ding, Selami Emanet, Mojtaba Talachian, Chase Cox, Michael Eller, Shengmin Guo
Summary: The study uses the solid-state additive friction stir deposition (AFSD) process to fabricate Al-Cu-Li 2050 alloy parts. The hardness distribution of the as-fabricated parts is unique due to the variations in the processing temperature profile. XRD results show the presence of secondary phases, and EDS mapping confirms the formation of alloying particles in the deposited matrix. The AFSD thermal-mechanical process results in a unique hardness distribution and reduced microhardness level in the components compared to the feedstock material.
Article
Materials Science, Multidisciplinary
Ting Luo, Wenshen Tang, Ruilin Wang, Shiwei Wang, Lv Xiao, Xinqi Yang
Summary: In this study, multi-layer single-pass deposits of high-performance Mg-8Gd-3Y-0.5Zr alloy were successfully prepared using force-controlled additive friction stir deposition (AFSD) with a high deposition rate. The microstructure and mechanical properties heterogeneity along the build direction and transverse direction of the final deposits were investigated. The results showed that the tensile properties of the as-deposited final deposits were superior to those of the extruded Mg-8Gd-3Y-0.5Zr alloy due to the evident grain refinement during deposition.
Article
Materials Science, Multidisciplinary
Priyanshi Agrawal, Ravi Sankar Haridas, Surekha Yadav, Saket Thapliyal, Abhijeet Dhal, Rajiv S. Mishra
Summary: The solid state nature of the AFSD additive manufacturing process provides advantages in terms of defect formation and microstructural refinement. This study investigates the process optimization, microstructural evolution, and recrystallization kinetics of AFSD deposited SS316. The as-deposited microstructure consists of equiaxed ultrafine grains, with an average grain size of around 5.0 +/- 0.5 μm. The observed necklace-type microstructure is attributed to discontinuous dynamic recrystallization during processing. The recrystallization kinetics of AFSD SS316 are characterized using the JMAK model.
MATERIALS CHARACTERIZATION
(2023)
Article
Metallurgy & Metallurgical Engineering
Li Huizhao, Wang Caimei, Zhang Hua, Zhang Jianjun, He Peng, Shao Minghao, Zhu Xiaoteng, Fu Yiqin
Summary: This paper summarizes the research progress of friction stir additive manufacturing (FSAM) technology at home and abroad. FSAM is fast-forming, has high additive efficiency, and provides environmental protection. It effectively avoids shrinkage, porosity, and other defects caused by other melt-additive methods during molding. The microstructures, properties, advantages, and disadvantages of different FSAM methods are discussed, along with the companies manufacturing FSAM equipment and the future development direction.
ACTA METALLURGICA SINICA
(2023)
Article
Chemistry, Physical
Congyuan Zeng, Hamed Ghadimi, Huan Ding, Saber Nemati, Abdelrahman Garbie, Jonathan Raush, Shengmin Guo
Summary: The study found that Al6061 alloy samples made with AFS-D exhibited a symmetrical layer-by-layer structure, uneven grain morphology distribution, and lower hardness compared to the feedstock.
Article
Materials Science, Multidisciplinary
G. Yang, W. Q. Zhang, J. Zhang, J. Z. Yi, Y. F. Cui
Summary: In this study, friction stir processing (FSP) was used to improve the microstructure and eliminate pore defects of WE43 magnesium alloy fabricated by laser deposition manufacturing (LDM).
Article
Materials Science, Multidisciplinary
Rajiv S. Mishra, Ravi Sankar Haridas, Priyanshi Agrawal
Summary: Additive manufacturing has revolutionized component manufacturing and qualification by providing opportunities for topological optimization. Friction stir additive manufacturing and additive friction stir deposition utilize intense shear deformation to create microstructures that exhibit improved mechanical properties compared to conventionally processed alloys. Optimal mechanical properties can be achieved through alloy design, although further research is needed to apply these processes to high-temperature materials.
SCIENCE AND TECHNOLOGY OF WELDING AND JOINING
(2022)
Article
Materials Science, Multidisciplinary
Z. Shen, S. Chen, L. Cui, D. Li, X. Liu, W. Hou, H. Chen, Z. Sun, W. Y. Li
Summary: The present investigation focuses on the localized microstructure evolution and mechanical performance of friction stir additive manufactured (FSAM) 2195 Al-Li alloy. Optical microscope, electron back scattered diffraction, and transmission electron microscopy techniques were used to characterize the microstructure, while microhardness and tensile testing measurements were conducted to evaluate the mechanical properties. The results showed that a multilayered stack of 2195 aluminum lithium alloy was successfully fabricated using FSAM, with fine equiaxed grains observed in the nugget zone. The mechanical properties were influenced by the distribution of precipitation phases and the size of grain boundaries.
MATERIALS CHARACTERIZATION
(2022)
Article
Materials Science, Multidisciplinary
Changshu He, Ying Li, Jingxun Wei, Zhiqiang Zhang, Ni Tian, Gaowu Qin, Xiang Zhao
Summary: Previous studies have shown that underwater friction stir additive manufacturing (FSAM) can effectively suppress the macro-scale softening of fabricated alloy builds. However, the problem of local softening, specifically the low hardness region at the bottom of each stir zone, remains prominent. This study investigates the use of a low quench sensitivity Al-Zn-Mg alloy and in-process water cooling to address the macro-scale and local softening issues in FSAM, ultimately improving the mechanical performance of the build.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2022)
Article
Metallurgy & Metallurgical Engineering
Sameehan S. Joshi, Shreyash M. Patil, Sangram Mazumder, Shashank Sharma, Daniel A. Riley, Shelden Dowden, Rajarshi Banerjee, Narendra B. Dahotre
Summary: This study investigated the additive friction stir deposition of AZ31B magnesium alloy using MELD (R) technology. The results showed that the additively produced samples had a refined grain structure, strengthened basal texture, and slightly higher hardness compared to the feed material. This research provides a pathway for solid state additive manufacturing of magnesium suitable for structural applications.
JOURNAL OF MAGNESIUM AND ALLOYS
(2022)
Article
Engineering, Manufacturing
Huizi Chen, Xiangchen Meng, Jialin Chen, Yuming Xie, Jinqi Wang, Shuming Sun, Yaobang Zhao, Junchen Li, Long Wan, Yongxian Huang
Summary: Additive manufacturing using metallic components is widely accepted in low-carbon productions, but there are still solidification defects in melting-based technologies. This study introduces a wire-based friction stir additive manufacturing (W-FSAM) method, which allows for the solid-state manufacturing of large metallic structures by continuously feeding wire materials. The W-FSAM technique, with its screwed transport structure and stirring probes, enables the production of large structures without kissing bond defects and with uniform, fine, and equiaxed grain microstructures. The ultimate tensile strength achieved by this solid-state additive manufacturing strategy is 111% of the wire base metal. The W-FSAM technique shows great potential for efficiently fabricating large structures with high performance.
ADDITIVE MANUFACTURING
(2023)
Review
Materials Science, Multidisciplinary
Ashish Kumar Srivastava, Nilesh Kumar, Amit Rai Dixit
Summary: The friction stir additive manufacturing (FSAM) method utilizes solid-state friction stir processing to develop multilayer components through layer by layer joining. This study highlights the working principle and past research work carried out by various authors using FSAM as a fabrication process, summarizing the experimental data, materials, process parameters, and mechanical properties of the resulting components. Additionally, the current scenario and future scope of FSAM in engineering sectors, along with estimated future trends, are also discussed.
MATERIALS SCIENCE AND ENGINEERING B-ADVANCED FUNCTIONAL SOLID-STATE MATERIALS
(2021)
Article
Materials Science, Multidisciplinary
Priyanka Agrawal, Sanya Gupta, Abhijeet Dhal, Ramprashad Prabhakaran, Lin Shao, Rajiv S. Mishra
Summary: Properties and radiation responses of a metastable high entropy alloy (HEA) exhibiting the transformation-induced plasticity (TRIP) effect were studied. The innovative engineering used to manufacture this HEA has demonstrated superior mechanical and corrosion properties compared to most advanced stainless steels in 3.5% NaCl. The microstructural evolution and corresponding mechanical response after irradiation were evaluated using detailed transmission electron microscopy and nanoindentation. The study reveals a change in the alloy's metastability with irradiation through a recovery mechanism, where the irradiation-induced transformation is reversed by the temperature-induced transformation, introducing the concept of self-healing made possible by the TRIP behavior of HEA.
JOURNAL OF NUCLEAR MATERIALS
(2023)
Article
Materials Science, Multidisciplinary
Priyanshi Agrawal, Ravi Sankar Haridas, Surekha Yadav, Saket Thapliyal, Abhijeet Dhal, Rajiv S. Mishra
Summary: The solid state nature of the AFSD additive manufacturing process provides advantages in terms of defect formation and microstructural refinement. This study investigates the process optimization, microstructural evolution, and recrystallization kinetics of AFSD deposited SS316. The as-deposited microstructure consists of equiaxed ultrafine grains, with an average grain size of around 5.0 +/- 0.5 μm. The observed necklace-type microstructure is attributed to discontinuous dynamic recrystallization during processing. The recrystallization kinetics of AFSD SS316 are characterized using the JMAK model.
MATERIALS CHARACTERIZATION
(2023)
Article
Engineering, Manufacturing
Ravi Sankar Haridas, Priyanka Agrawal, Saket Thapliyal, Priyanshi Agrawal, Abhijeet Dhal, Shivakant Shukla, Le Zhou, Yongho Sohn, Rajiv S. Mishra
Summary: This study investigates the tensile and high cycle fatigue behavior of a novel Al-Ni-Ti-Zr alloy with a heterogeneous microstructure. The alloy exhibits excellent strength-ductility synergy and fatigue performance, attributed to multiple crack retardation mechanisms and favorable crack propagation pathways. Additionally, a probabilistic model is used to estimate the fatigue life of the alloy based on the stochastic microstructure.
ADDITIVE MANUFACTURING
(2023)
Article
Nanoscience & Nanotechnology
Priyanshi Agrawal, Saket Thapliyal, Priyanka Agrawal, Abhijeet Dhal, Ravi Sankar Haridas, Sanya Gupta, Rajiv S. Mishra
Summary: A paradigm shift in the composition of high entropy alloys (HEAs) has provided new opportunities for microstructural engineering, particularly in laser powder bed fusion (LPBF) additive manufacturing (AM) which allows for fine-tuning of microstructures. This study focused on the microstructural evolution of a metastable dual phase HEA during LPBF AM and established a processing window for the alloy. The microstructure of the alloy was governed by the LPBF process parameters, which influenced the final phase fraction and metastability alteration. Additionally, the study observed variations in stacking fault morphology and nanomechanical behavior of the alloy with changes in process parameters.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Nanoscience & Nanotechnology
Supreeth Gaddam, Mohan Sai Kiran Kumar Yadav Nartu, Advika Chesetti, Srinivas A. Mantri, Rajiv S. Mishra, Narendra B. Dahotre, Rajarshi Banerjee
Summary: Direct laser deposition of a Ni-NbC composite using the laser engineered net shaping process resulted in the formation of a complex hierarchical multi-phase microstructure. The composite consisted of a primary dendritic Ni-rich gamma phase with an interdendritic gamma + NbC eutectic, and further decomposed into a lamellar mixture of gamma + delta phase (Ni3Nb). The study also established the sequence of phase evolution in this complex hierarchical in-situ composite system.
SCRIPTA MATERIALIA
(2023)
Article
Materials Science, Multidisciplinary
Abhijeet Dhal, Priyanka Agrawal, Ravi Sankar Haridas, Supreeth Gaddam, Aishani Sharma, Digvijay Parganiha, Rajiv S. Mishra, Hirotsugu Kawanaka, Shinji Matsushita, Yusuke Yasuda, Seung Hwan C. Park, Wei Yuan
Summary: This paper investigates the complex deformation mechanisms of Inconel 718 (IN718) superalloy processed by laser powder-bed fusion additive manufacturing (L-PBFAM) and heat treatment using high-resolution nanoindentation. The results reveal a crystal orientation dependency of modulus and hardness, as well as complex microscale strength variation due to thermal cycles. The heat treatment activates multiple precipitation-strengthening mechanisms, leading to a significant increase in yield strength. The orientation-dependent hardness distribution is contributed by the high mechanical anisotropy and coherency strengthening of precipitates.
Article
Materials Science, Multidisciplinary
Ravi Sankar Haridas, Anurag Gumaste, Priyanshi Agrawal, Surekha Yadav, Rajiv S. Mishra
Summary: The advent of high entropy alloys (HEAs) has allowed for precise tuning of alloy composition to develop solid-solution alloys with excellent physical and mechanical properties. In this study, dissimilar friction stir welding (FSW) was used to integrate the beneficial mechanical properties of two different HEAs, resulting in a refined microstructure and enhanced mechanical performance. The improved and integrated mechanical properties in the stir zone (SZ) were correlated with the microstructure, existing recrystallization mechanisms, and active deformation mechanisms in both alloys.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Nanoscience & Nanotechnology
Jacob Weiss, Daniel J. Savage, Sven C. Vogel, Brandon A. Mcwilliams, Rajiv S. Mishra, Marko Knezevic
Summary: The evolution of microstructure, strength, and ductility of a metastable high entropy alloy (HEA) was investigated in this study. By controlling the alloy composition and processing conditions, significant improvements in mechanical properties could be achieved. The strain-induced martensitic transformation contributed to plastic strain accommodation and rapid strain hardening, resulting in high strength and ductility of the alloy.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Engineering, Manufacturing
Przemyslaw Golebiewski, Pawel Wienclaw, Jaroslaw Cimek, Pawel Socha, Dariusz Pysz, Adam Filipkowski, Grzegorz Stepniewski, Olga Czerwinska, Ireneusz Kujawa, Ryszard Stepien, Rafal Kasztelanic, Andrzej Burgs, Ryszard Buczynski
Summary: We report the development of a 3D printing process for producing soft glass optical fibers. The process involves direct printing using a miniaturized crucible and depositing straight horizontally-oriented lines to replace traditional assembly techniques. Experimental results demonstrate good performance of the printed photonic crystal fiber preform.
ADDITIVE MANUFACTURING
(2024)
