Research Progress of Friction Stir Additive Manufacturing Technology

doi:10.11900/0412.1961.2022.00436

Acta Metall Sin

2023, Vol. 59

Issue (1): 106-124 DOI: 10.11900/0412.1961.2022.00436

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Research Progress of Friction Stir Additive Manufacturing Technology

LI Huizhao¹, WANG Caimei¹, ZHANG Hua¹(

), ZHANG Jianjun¹, HE Peng², SHAO Minghao¹, ZHU Xiaoteng¹, FU Yiqin³

1.School of Mechanical Engineering, Beijing Institute of Petrochemical Technology, Beijing 102617, China
2.State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China
3.China National Petroleum Corporation, Beijing 100724, China

Cite this article:

LI Huizhao, WANG Caimei, ZHANG Hua, ZHANG Jianjun, HE Peng, SHAO Minghao, ZHU Xiaoteng, FU Yiqin. Research Progress of Friction Stir Additive Manufacturing Technology. Acta Metall Sin, 2023, 59(1): 106-124.

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Abstract

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. In addition, as a solid-phase additive technology, it effectively avoids shrinkage, porosity, and other defects caused by other melt-additive methods during molding. Currently, reported FSAM methods can be roughly divided into four categories: axial additive manufacturing, radial additive manufacturing, consumable friction-stir tool additive manufacturing, and superimposed plate additive manufacturing. The microstructures and properties of friction stir, laser, and arc additive samples are listed in detail. The advantages and disadvantages of the different additive methods and their application fields are expounded. The companies of friction stir additive equipment, the preliminary applications, and the development direction of friction stir additive equipment designed in the future are introduced. It lays a foundation for further application of friction stir additive technology.

Key words: solid phase additive friction stir additive manufacturing microstructure mechanical property

Received: 01 September 2022

ZTFLH:

TG439.8

Fund: State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology(AWJ-23M08);Cross-Disciplinary Science Foundation from Beijing Institute of Petrochemical Technology(BIPTCSF-013)

About author: ZHANG Hua, professor, Tel: 13521880280, E-mail: huazhang@bipt.edu.cn

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00436 OR https://www.ams.org.cn/EN/Y2023/V59/I1/106

Fig.1 Classification of friction stir additive manufacturing (FSAM) methods

Fig.2 Working principle diagram of hot wire friction additive device equipment^[56]
(a) device working diagram (b) upward view of friction tool head

Fig.3 Schematics of a stationary shaft shoulder cavity additive device
(a) schematics of additive structure of stationary shaft shoulder cavity
(b) enlarged schematic diagram of cavity and feed hole

Fig.4 Schematics of a spiral groove additive device
(a) device working diagram
(b) lower end face structure of the shaft shoulder
(c) schematic of stirring pin structure

Fig.5 Schematic of spiral groove powder additive device

Fig.6 Schematics of a powder additive device for the feed hole^[61]
(a) working diagram of friction head (b) top view of the friction head

Fig.7 Schematics of an additive device for square raw material strips
(a) 3D cross-sectional view of the additive device
(b) plane cutaway view of the container of the system

Fig.8 Schematic of the short rod material additive device

Fig.9 Schematics of a continuous additive device for raw material rod^[65]
(a) schematic of the device structure
(b) sectional view of the feeding mechanism
(c) schematic of the end face of the stirring head
(d) schematic of the upper clutch module
(e) schematic of the lower clutch module

Fig.10 Schematic of a granular additive device

Fig.11 Schematics of a semi-solid-state additive device
(a) device working diagram (b) device sectional view

Fig.12 Schematics of a radial circle-by-turn additive device^[69]
(a) device structure diagram
(b) bottom view of the stationary shaft shoulder and the stirring head
(c) schematic of stirring head structure
(d) schematic of the structure of the static shoulder body
(e) schematic of the mold structure
(f) schematic of the radial working process

Fig.13 Schematics of a radial layer-by-layer additive device
(a) consumable rod lateral additive manufacturing
(b) overlay additive strips for lateral additive manufacturing

Fig.14 Schematics of an additive device applied to cooling^[75]
(a) schematic of the three-dimensional structure of the additive device
(b) schematic of the contact between the water cooled blocks and the additive test plates

Table 1 Properties and microstructure characteristics of FSAM samples of different materials^[71,78-80]

Table 2 Microstructure characteristics of FSAM, laser and arc additive samples^[32,81,82]

Fig.15 Comparison of microstructures of samples after additive manufacturing
(a) microstructure of the central core region of friction stir additive 2024 aluminum alloy^[32]
(b) cross-sectional microstructure of laser additive manufactured 2024-T6 aluminum alloy^[81]
(c) longitudinal sectional microstructure of laser additive manufactured 2024-T6 aluminum alloy^[81]
(d) microstructure of arc additive manufactured AA2024 aluminum alloy (ED—equiaxed dendrite, END—equiaxed non-dendrite, CD—columar dendrite)^[82]

Table 3 Comparison of tensile property of three ways of additive parts^{[32,74,81-87]}

FSAM	Additive form	Advantage		Disadvantage	Scope of application
method
Axial	Wire material	Low cost; multiple wire	Sustainable	Complex	Carrier rockets, ships; automobiles
direction	Wire material	Low cost; multiple wire	uninterrupted	structure;	and other fields; suitable for
		feeding holes; high			and other fields; suitable for
		feeding holes; high			aluminum alloy ribbed panel
		efficiency^[59]	additive;	material	aluminum alloy ribbed panel
		efficiency^[59]	additive;	material	structure, inlet, complex frame
			high additive	residue in	structure, inlet, complex frame
			high additive	residue in	beam structure of high efficiency,
			efficiency	equipment	beam structure of high efficiency,
			efficiency	equipment	low cost manufacturing^[58]
					low cost manufacturing^[58]
	Powder	Changeable molding			Preparation of new alloys difficult to prepare in equilibrium metallurgical processes^[61]
		parameters and additive
		powder ratio^[61]
	Raw material	High material utilization			Ultrafine grained homogeneous
	rod	High material utilization			Ultrafine grained homogeneous
	rod	and small processing			AM parts and thermoplastic
		allowance^[63]; expanded			polymers for various metals
		additive geometry^[62]			and alloys^[65]
	Granules	Diversified materials and			FSAM of gradient composites^[67]
		sizes^[67]
	Various	Manufactruing of composite			FSAM of gradient composites^[67]
	materials can	materials^[67]
	be added
Radial	Circle-by-turn	High additive quality; high load-bearing		Low additive	Manufacture of raw materials such
direction		additive components; high bonding strength^[69]		efficiency	as metals and metal matrix
					composites with different
					morphologies^[69]
	Layer-by-layer	High material utilization; non-polluting			Manufacture of dissimilar alloy
		powder raw material; no structural			and light alloy structural parts^[71]
		limitations^[71]
Consumable	Raw bar	Simple equipment method; simple operation			AM of light metal structures such
friction	material	steps; low cost; short manufacturing time;			as aluminum alloy and magnesium
stir tool		fast forming speed^[72]			alloy and stainless steel
Superimposed	Lap based on	Simple additive method; simple operation			Applicable to aerospace,
plate	FSW	steps; low cost			automotive parts, ships, and
	Stationary	No grinding or cutting after additive			rail transportation fileds; and
	shoulder	manufacturing			AM of aluminum alloy, magnesium
	Apply cooling	Effectively reduceing the thermal effect^[75]			alloy and other light metal
	Stirring head	The material mixes more fully^[76]			structures, and stainless steel
	with special
	structure
	Add preset	High bonding strength; high joint quality;
	heterogeneous	high fracture strength^[77]
	metal
	interlayer

Table 4 Advantages and disadvantages and applicable fields of FSAM different additive methods^{[58,59,61-63,65,67,69,71,72,75-77]}

Table 5 FSAM equipment units and the applications

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