Friction Stir Additive Manufacturing—A Review
19
the concave or flat shoulder of the tool which is pushed down on the workpiece
through axial force helps in containing the third body region. The sustainability
of a given friction stir technology is determined by the design, material section,
performance and durability of the tool [43–50].
3 Friction Stir Additive Manufacturing (FSAM)
Friction-based joining for additive manufacturing was patented by White in 2004
[51], and Airbus published the first report [35] that reported the use of friction
stir technology for additive manufacturing of metals in 2006, but only recently the
possibility to build 3-D layers through FSAM has been explored extensively.
Friction stir additive manufacturing is a welding technique of friction stir-based
family as mentioned in Fig. 2. It is a novel additive manufacturing technique that
employs part-by-part formation of the desired product. Although this technique has
been introduced in 2004, its ability to realize higher productivity and lower loss of
material had been envisaged closely afterwards [52], its actual performance in lighter
constructions for essential functions has been critically evaluated and explored only
recently. FSAM, being a solid-state technology, obviously has several advantages
over its fusion counterparts as mentioned earlier in the paper.
The friction stir-based additive manufacturing (FSAM) processes are further classified based on the joining process as Type 1 and Type 2 [41]. Type 1 is a combination
of additive manufacturing and friction deposition, while Type 2 is a combination of
additive manufacturing and friction stir welding.
3.1 Type 1 Friction Stir Additive Manufacturing
In the type 1 FSAM, rotary friction welding is combined with friction deposition
process. This family of operations employs a rotating tool that is rubbed on the
workpiece to generate the frictional heat for joining. The distinguishing characteristic of these processes that a consumable tool is employed and the third body region
is developed in the tool itself. The tool deposits a layer on the surface of the workpiece through which it rotates and translates. The two major processes included here
are friction surfacing and friction deposition, and both work basically on the same
principle, solid-state material transfer from a consumable rod onto the substrate by
rubbing.
Friction surfacing is a solid-state cladding technology [53]. Friction surfacing was
first patented in 1941 by Klopstock and Neelands [54], but only recently the possibility for additive manufacturing through this technique has been explored [55]. It is a
promising technology which is used for depositing bonded coatings on the substrate
[56]. The rotating consumable tool is forced down on a flat substrate, and heat is
19
the concave or flat shoulder of the tool which is pushed down on the workpiece
through axial force helps in containing the third body region. The sustainability
of a given friction stir technology is determined by the design, material section,
performance and durability of the tool [43–50].
3 Friction Stir Additive Manufacturing (FSAM)
Friction-based joining for additive manufacturing was patented by White in 2004
[51], and Airbus published the first report [35] that reported the use of friction
stir technology for additive manufacturing of metals in 2006, but only recently the
possibility to build 3-D layers through FSAM has been explored extensively.
Friction stir additive manufacturing is a welding technique of friction stir-based
family as mentioned in Fig. 2. It is a novel additive manufacturing technique that
employs part-by-part formation of the desired product. Although this technique has
been introduced in 2004, its ability to realize higher productivity and lower loss of
material had been envisaged closely afterwards [52], its actual performance in lighter
constructions for essential functions has been critically evaluated and explored only
recently. FSAM, being a solid-state technology, obviously has several advantages
over its fusion counterparts as mentioned earlier in the paper.
The friction stir-based additive manufacturing (FSAM) processes are further classified based on the joining process as Type 1 and Type 2 [41]. Type 1 is a combination
of additive manufacturing and friction deposition, while Type 2 is a combination of
additive manufacturing and friction stir welding.
3.1 Type 1 Friction Stir Additive Manufacturing
In the type 1 FSAM, rotary friction welding is combined with friction deposition
process. This family of operations employs a rotating tool that is rubbed on the
workpiece to generate the frictional heat for joining. The distinguishing characteristic of these processes that a consumable tool is employed and the third body region
is developed in the tool itself. The tool deposits a layer on the surface of the workpiece through which it rotates and translates. The two major processes included here
are friction surfacing and friction deposition, and both work basically on the same
principle, solid-state material transfer from a consumable rod onto the substrate by
rubbing.
Friction surfacing is a solid-state cladding technology [53]. Friction surfacing was
first patented in 1941 by Klopstock and Neelands [54], but only recently the possibility for additive manufacturing through this technique has been explored [55]. It is a
promising technology which is used for depositing bonded coatings on the substrate
[56]. The rotating consumable tool is forced down on a flat substrate, and heat is