Friction Stir Processing Service

Friction stir processing (FSP) is a technique for changing the properties of metals through localized plastic deformation. Developed from friction stir welding (FSW), which allows for the joining of materials without the creation of a heat affected zone, FSP involves the insertion of a non-consumable tool into the workpiece. This tool then revolves in a stirring motion as it is moved laterally along the workpiece. The approach is used to selectively modify alloys such that the resulting components and assemblies exhibit locally enhanced properties and deliver high materials performance in the locations most needed.

The FSP is used when metals properties want to be improved using other metals for support and improvement of the first. This is promising process for the automotive and aerospace industries where new material will need to be developed to improve resistance to wear, creep, and fatigue.

In friction stir processing (FSP), a rotating tool is used with a pin and a shoulder to a single piece of material to make specific property enhancement, such as improving the material's toughness or flexibility, in a specific area in the micro-structure of the material via fine grain of a second material with properties that improve the first.

STEMart provides comprehensive friction stir processing services to solve your problems in production and research and meet relevant regulations and international standards, thus improving the quality and performance of your products.

Advantages

FSP offers a technique for mixing materials in a solid state to achieve microstructural refinement densification and homogeneity. This means that the material doesn’t need to be melted and then remold to cool and form.

The microstructure and mechanical properties can be controlled in the processed zone by optimizing the tool design. For example, FSP has been shown to modify metallic alloys so that they can be bent by as much as 30 degrees, whereas they would normally only be able to bend to 7 degrees.

Applications

• Aluminium Surface Composites:

FSP can be used to enhance the mechanical properties and corrosion resistance of the surface layers of aluminum composites using friction stir processing parameters. The parameters, such as the tool shoulder's diameter and rotational speed, affect the material surface properties. In this instance, the lower the tool shoulder diameter and the faster the tool rotational speed, the higher the surface hardness.

• Casting:

Casting is a relatively inexpensive way of producing metallic parts, but they can include flaws such as porosity or microstructural defects. A microstructure evolution can be delivered through FSP, creating a wrought microstructure for cast components while eliminating defects. Reducing the grain size in cast metal parts through stirring will homogenize the material, increasing strength while lowering ductility.

• Metal Matrix Composite Fabrication:

Metal matrix composites can be fabricated using FSP at the nugget zone to provide changed properties. This can be used for a range of composites including nanocomposites.

• Powder Metallurgy:

FSP can improve the properties of powder metal objects, particularly those of aluminum powders that may have an aluminum oxide film on the surface of the granules. This oxide can harm the fatigue properties, fracture toughness, and ductility of the workpiece. Friction stir processing can be used as an alternative to extrusion or forging where a localized treatment is required.

For more information about our friction stir processing services services and equipment, please contact us.