16
D. Shah and V. J. Badheka
1.3 Drawbacks of Conventional Metal Additive
Manufacturing (MAM) Techniques
These conventional techniques have various drawbacks. Many of the feasible
methods embroil following problems:
1. The parts produced exhibit cast microstructures and inhomogeneous composition
due to segregation which is a consequence of melting and solidification [30].
2. Alloys that are susceptible to solidification cracking like aluminium, magnesium,
etc., cannot be produced with sound properties with these methods.
3. Mechanical properties can be affected due to thermal residual stresses.
4. Fabrication of multi-alloy structure is constrained by metallurgical compatibility.
5. These methods are expensive, and the production is also limited due to low
deposition rates (less than 1 g/min) [31].
Taking into account the discussion up till now, the objective of the paper is to
explore the relatively uncharted field of FSAM technologies. This review aims at
presenting an overview of the emerging field of friction stir-based additive manufacturing techniques and presents the effect and opportunities that it holds in the context
of the future of the manufacturing industry. The paper has been categorized into four
parts: (1) introduction of friction-based technologies in MAM, (2) basics of FSAM
technologies, (3) advantages and the potential of FSAM technologies and (4) recent
advancements and literature regarding FSAM.
2 Friction-Based Manufacturing
2.1 Introduction of Solid-State Welding
Solid-state welding (SSW) process family consists of technologies that are used to
fabricate components at temperatures that are essentially below the melting point
of the workpiece in the process. Strong bonding is achieved through deformation
and diffusion of material from one place to another with the help of mechanical,
electrical or thermal energy. There is no melting involved in these processes, and all
the hindrances involved with conventional techniques as stated in Sect. 1.3 can be
surpassed by employing solid-state techniques. Thus, they hold a prominent place in
the field of manufacturing technologies. Solid-state welding family consists of cold
welding, ultrasonic welding, friction and friction stir welding, diffusion bonding,
resistance welding and explosion welding [32]. In principle, many SSW welding
processes can be utilized for additive manufacturing while ultrasonic welding and
friction-based welding are the most widely utilized techniques currently.
The use of SSW additive technology is being explored for the replacement of
the conventional techniques especially in the aerospace and automotive industry.
D. Shah and V. J. Badheka
1.3 Drawbacks of Conventional Metal Additive
Manufacturing (MAM) Techniques
These conventional techniques have various drawbacks. Many of the feasible
methods embroil following problems:
1. The parts produced exhibit cast microstructures and inhomogeneous composition
due to segregation which is a consequence of melting and solidification [30].
2. Alloys that are susceptible to solidification cracking like aluminium, magnesium,
etc., cannot be produced with sound properties with these methods.
3. Mechanical properties can be affected due to thermal residual stresses.
4. Fabrication of multi-alloy structure is constrained by metallurgical compatibility.
5. These methods are expensive, and the production is also limited due to low
deposition rates (less than 1 g/min) [31].
Taking into account the discussion up till now, the objective of the paper is to
explore the relatively uncharted field of FSAM technologies. This review aims at
presenting an overview of the emerging field of friction stir-based additive manufacturing techniques and presents the effect and opportunities that it holds in the context
of the future of the manufacturing industry. The paper has been categorized into four
parts: (1) introduction of friction-based technologies in MAM, (2) basics of FSAM
technologies, (3) advantages and the potential of FSAM technologies and (4) recent
advancements and literature regarding FSAM.
2 Friction-Based Manufacturing
2.1 Introduction of Solid-State Welding
Solid-state welding (SSW) process family consists of technologies that are used to
fabricate components at temperatures that are essentially below the melting point
of the workpiece in the process. Strong bonding is achieved through deformation
and diffusion of material from one place to another with the help of mechanical,
electrical or thermal energy. There is no melting involved in these processes, and all
the hindrances involved with conventional techniques as stated in Sect. 1.3 can be
surpassed by employing solid-state techniques. Thus, they hold a prominent place in
the field of manufacturing technologies. Solid-state welding family consists of cold
welding, ultrasonic welding, friction and friction stir welding, diffusion bonding,
resistance welding and explosion welding [32]. In principle, many SSW welding
processes can be utilized for additive manufacturing while ultrasonic welding and
friction-based welding are the most widely utilized techniques currently.
The use of SSW additive technology is being explored for the replacement of
the conventional techniques especially in the aerospace and automotive industry.