Comarision of three processes

05/04/2024 Prof. Adepu Kumar - Department of Mechanical Engin 1

eering, NITW
Introduction-Friction Stir Additive Manufacturing

• Friction Stir Additive Manufacturing(FSAM) is a solid-state

additive manufacturing technology like ultrasonic consolidation

and adhesive backing method.

• FSAM working principle is derived from the lap welding in

friction stir welding (FSW).

• The non-consumable tool rotating and travelling over the

plates will join the plates.

• FSAM can join the plates of higher thickness which is not

possible with ultrasonic consolidation and adhesive backing

method.
Applications:

Stringers of Aircraft FGM Stiffeners for vessels

• Stringers in aircraft fuselage used to transfer loads from skin to frame are made FSAM in recent times.

• Functionally Graded materials (FGM) are very popular and potential materials which show different properties at

different parts. Example of such application can be a gear which has to be hard and wear resistant on the outer part

and soft and tough from inside. FGM’s can be easily made by FSAM.

• Stiffeners used to improve strength of vessels are made by FSAM.

 Functionally Graded Material (FGM)(AA5083-AA6061-AA5083)

• 3-layer FGM is fabricated with the configuration shown in figure using AA5083 & AA6061.
• Process parameters are selected based on laminated composite analysis. Which are as follows,
Process Parameters
Parameter Value
Rotational speed 1200 rpm AA5083
Transverse speed 45mm/min
AA6061
No. of passes 2 (50%
overlap)
AA5083
Tilt angle 1°
FGM configuration
Overlap in FSW

OM Observations:
• Proper material flow took pace between the three layers and joint has been formed.
• As the FGM is made with 50% overlap, multiple stir-zones can be seen in full OM image.
• Just beside Stir-zone we can observe 3 layers and distinguish them based on color but in SZ we cannot distinguish,
which confirms proper intermixing of material.
Advances in Materials Processing

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 Overview
• Need in Advances in Manufacturing Technology
• Introduction to composite materials
• Preparation of Composite materials by various process
Stir casting
Solid state welding process
Friction stir processing

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 Need in Advances in Manufacturing Technology

• Customer demand
• High performance with low cost
• High strength to weight ratio
• High Durability with less corrosion

• Development of New Materials

• Bulk form of the part or product made.
• Applications

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 Need of Composite materials
• The continued integration of
lightweight composites into automotive
and transportation will help alleviate
the United Sates dependence on
foreign oil.
• In particular, the US dependence on
foreign oil supplied by other countries .
• Composite materials integrated into
aerospace, automotive, trucking, and
mass transit will all have fuel saving
benefits.
• Products manufactured with
composites will require less energy to
transport or ship than traditional
materials. 8
 History
• The earliest man-made composite materials were straw and mud combined to
form bricks for building construction.

• Concrete is also a composite material, and is used more than any other man-
made material in the world. It consists of a binder (cement) and a reinforcement
(gravel).

• Composite materials occur in nature. For example, Wood is a natural composite

consisting of cellulose as the fiber and lignin as the matrix.

• The first artificial fiber reinforced plastic was Bakelite (thermosetting phenol
formaldehyde resin) which was developed in 1907. 9
 Composite materials
• Composite materials are made from two or more constituent materials with
significantly different physical or chemical properties, that when combined,
produce a material with characteristics different from the individual
components.
• The individual components remain separate and distinct within the finished
structure.
• In composite material the reinforcements can be fibers, particulates or whiskers,
and the matrix materials can be metals, plastics, or ceramics.

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 Composites are defined as materials
with following criteria
(a) Must be a combination of at least two chemically distinct materials
with distinct interphase separating the constituents.

(b) Must be combined three dimensionally.

(c) Should be created to obtain properties which would not otherwise be

achieved by any of the individual constituent.

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Engineering Materials

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 COMPOSITES

Particle Reinforced Fiber Reinforced Structural

Large Particles Dispersion Continuous Discontinuous Laminates Sandwich

Strengthen (Aligned) (short) Panels

Aligned Randomly
Oriented

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Materials Selection Charts

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 Composites vs. Metals
Comparison based on six primary material selection parameters

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 Composite Benefits
CMCs: Increased toughness PMCs: Increased E/r
ceramics
Force 10 3
particle-reinf E(GPa) PMCs
10 2
10 metal/
fiber-reinf Metal alloys
1

un-reinf .1 G=3E/8 polymers

K=E
.01
.1 .3 1 3 10 30
Bend displacement Density, r [mg/m3]
-4
10
6061 Al
MMCs: Increased -6
10
creep resistance
-8 6061 Al
ess (s ) 10
-1
w/SiC
whiskers
-10 s
10 20 30 50 100 200 (MPa) 17
 Advantages of Composites
Specific Strength and Stiffness

Tailored Design

Fatigue Life

Dimensional Stability

Corrosion Resistance

Cost-Effective Fabrication

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 Applications

• Aerospace industry

• Sports Industry

• Automotive Industry

• Home Appliance Industry

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Application of advanced composite materials in Boeing 757-200 commercial
aircraft 21
 Metal Matrix Composites (MMCs’)

• A metal matrix composite (MMC) is a composite material with at least two

constituent parts, one being a metal. The other material may be a different
metal or another material, such as a ceramic or organic compound.

• When at least three materials are present, it is called a hybrid composite.

• An MMC is complementary to a cermet.

• MMC’s are made by dispersing a reinforcing material into a metal matrix.

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 Metal Matrix Composites (MMCs’)
The metal matrix composites have various advantages over other types of
composites.

Such as

• High strength,

• High modulus,

• High toughness and impact properties,

• Low sensitivity to changes in temperature or thermal shock,

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 Applications
• High performance tungsten carbide cutting tools.
• Tank armors may be made from metal matrix composites
• Automotive parts like (Disk breaks (20% SiC reinforced Al-Cu alloy), rotors, disc brake calipers,
pushrods, driveshaft, cylinder liners and engine's cylinder sleeves etc..) use MMCs. (Company
Name: Lotus Elise, Porsche, Ford, Honda, Toyota etc..).
• Jet's landing gear.
• Specialized Bicycles.
• Space craft applications.
• MMCs such as B/Al, Gr/Al, Gr/Mg, and Gr/ Cu have been manufactured by diffusion bonding
for prototype spacecraft components such as tubes, plates, and panels.
• Aircraft components, space systems and high-end or "boutique" sports equipment.
• Electronic packaging and thermal-management applications.
• Potential applications included joints and attachment fittings for truss structures, electronic
packages, thermal planes, mechanism housings, and bushings. 24
 Applications
Discontinuously reinforced aluminum MMCs for
electronic packaging applications
Cast SiC/Al
attachment
fittings

P100/AZ91C
Gr/Mg tubes
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Metal-Matrix Composite Materials and
Applications

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MMCs’ Applications in Aerospace

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 Types of MMCs’
There are different types of metal matrix composites on the basis of reinforcement in
MMC.
such as
(a) Particle reinforcement;
(b) Short fiber reinforcement;
(c) Continuous fiber reinforcement;
(d) Laminate reinforcement.

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 Manufacturing methods
1. Liquid state methods

2. Solid state methods

1. Powder metallurgy

2. Friction stir processing

3. Diffusion bonding

3. Semi-solid state methods

4. Vapor deposition methods

5. In-situ fabrication technique 29

 Liquid State Fabrication of Metal Matrix
Composites
• It involves incorporation of dispersed phase into a molten matrix metal, followed by its
solidification.

• In order to provide high level of mechanical properties of the composite, good

interfacial bonding (wetting) between the dispersed phase and the liquid matrix should
be obtained.

• Wetting improvement may be achieved by coating the dispersed phase particles

(fibers).

• Proper coating not only reduces interfacial energy, but also prevents chemical
interaction between the dispersed phase and the matrix. 30
 Stir Casting
• It is a liquid state method of composite
materials fabrication, in which a
dispersed phase (ceramic particles, short
fibers) is mixed with a molten matrix
metal by means of mechanical stirring.
• The simplest and the most cost effective
method of liquid state fabrication.
• The liquid composite material is then cast
by conventional casting methods and may
also be processed by conventional Metal
forming technologies.
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Stir Casting Machine

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 Factors Affecting Outcomes Of Al-MMCs
• Factors affecting the outcome Al-MMCs are reaction at the interface, wettability,
shape and size of reinforcing material volume fraction of reinforcing material and
fabrication methods.
• Reaction at the interface

• Wettability (It is the tendency of one fluid to spread on, or adhere to, a solid surface in the
presence of other immiscible fluids)

• Distribution of reinforcing material

• Strengthening mechanism

• Grain size and reinforcing particle size

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• Fabrication methods
 Reaction at the Interface
• It is always imperative that some degree of reaction takes place at the interface. It is Essential for
developing strong interfacial bond which allows efficient transfer of load from matrix to
reinforcing material Reaction in Al/SiC MMC at interface is
4 Al + 3 SiC < – > Al3C4 + 3 Si
• The controlled reaction is good as Al3C4 layer at the interface improves offset yield strength,
ultimate tensile strength, work hardening rate with a slight reduction in ductility. On contrary if
it is allowed to grow, the consequences are
• It deteriorates SiC reinforcement
• Al3C4 being brittle degrades mechanical properties of the composite

• Method to avoid formation of Al3C4are

• Chemical coating of reinforcing material act as a barrier for reaction.
• In squeeze casting method due to high rate of heat transfer and undercooling less time is
available for reaction to take place. 34
 Wettability
• It is the ability of liquid to wet the surface. It depends on surface tension of liquid. It is
essential as it leads to a good interfacial bonding. Methods to enhance wettability are as
mentioned below
• (a) Addition of mg to molten Al matrix reduces surface tension of the matrix.
• (b) Heating of reinforcing material (contact angle for SiC at 900◦C is 150 degree and
at 1100 ◦C is 42 degree).
• (c) Chemical coating of reinforcing material (coating of SiC with Ni / chromium carbide).
• (d) Application of pressure as in squeeze casting..
• (e) Use of mechanical force such as steering.
• (f) Use of ultrasonic energy to steer the melt.
• (g) Addition of chemical that improves wettability ( wettability of B4C improved by
adding K2TiF6 salt Al melt.
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 Distribution Of Reinforcing Material
• Homogeneous distribution of reinforcing materials enhances mechanical
properties. Methods to avoid agglomeration/clustering during addition of
reinforcing materials are as given below (it is needed as it deteriorates
mechanical properties of Al-MMCs).
• a)Addition of reinforcing material when melt is in semi-solid state
(Rheocasting).
• b) Steer casting and then use of secondary processing method like extrusion.
• c) Squeeze casting method
• d) Powder metallurgy route of processing. Use of ultrasonic vibration.
• e) Double steering method.
• f) Two steps addition of reinforcing material.
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