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Additive Friction Stir Deposition

  • 1st Edition - July 19, 2022
  • Latest edition
  • Author: Hang Z. Yu
  • Language: English

Additive Friction Stir Deposition is a comprehensive summary of the state-of-the-art understanding on this emerging solid-state additive manufacturing technology. Sections… Read more

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Description

Additive Friction Stir Deposition is a comprehensive summary of the state-of-the-art understanding on this emerging solid-state additive manufacturing technology. Sections cover additive friction stir deposition, encompassing advances in processing science, metallurgical science and innovative applications. The book presents a clear description of underlying physical phenomena, shows how the process determines the printing quality, covers resultant microstructure and properties in the as-printed state, highlights its key capabilities and limitations, and explores niche applications in repair, cladding and multi-material 3D printing.

Serving as an educational and research guide, this book aims to provide a holistic picture of additive friction stir deposition-based solid-state additive manufacturing as well as a thorough comparison to conventional beam-based metal additive manufacturing, such as powder bed fusion and directed energy deposition.

Key features

  • Provides a clear process description of additive friction stir deposition and highlights key capabilities
  • Summarizes the current research and application of additive friction stir deposition, including material flow, microstructure evolution, repair and dissimilar material cladding
  • Discusses future applications and areas of research for this technology

Readership

Researchers from universities, institutes, and companies with an interest in metal additive manufacturing; practicing engineers in manufacturing industry; undergraduate and higher degree research students. Educator, entrepreneur, and general audience

Table of contents

Chapter 1. Introduction

1.1. Additive Manufacturing for Metals

1.2. Solid-State Metal Additive Manufacturing

1.3. Additive Friction Stir Deposition

1.4. Organization of the Book

Chapter 2. Process Fundamentals

2.1. Elements of Friction Theory

2.2. Fundamentals of Heat and Mass Transfer

2.3. Basic Principle of Additive Friction Stir Deposition

2.4. Establishment of an Integrated In Situ Monitoring System: Real-time Measurement of Temperature, Force, Torque, and Material Flow

2.5. Temperature Evolution in the Deposited Material and Substrate

2.6. Force and Torque Evolution

2.7. In Situ Visualization of Material Rotation and Flow

2.8. Correlation of the Material Flow Behavior to Temperature, Force, and Torque Evolution

2.9. Summary

Chapter 3. Material Flow Phenomena

3.1. Plasticity and Finite Deformation Theory

3.2. Elements of Fluid Mechanics

3.3. Previous Experimental Studies on Material Flow in Friction Stir Welding

3.4. Design of Tracer Experiments for Material Flow Investigation in Additive Friction Stir Deposition

3.5. Flow Path of the Center Volume of Feed Material

3.6. Flow Path of the Edge Volume of Feed Material

3.7. Material Deformation and Flow at the Interface

3.8. Summary

Chapter 4. Dynamic Microstructure Evolution

4.1. Elements of Microstructure Evolution

4.2. Dynamic Recrystallization Mechanisms

4.3. Thermomechanical History in Additive Friction Stir Deposition

4.4. Characteristics of the Resulting Microstructures by Additive Friction Stir Deposition

4.5. Dynamic Microstructure Evolution along the Flow Path of an Al-Cu Alloy

4.6. Processing-Microstructure Linkages of Al-Mg-Si and Cu

4.7. Dynamic Phase Evolution

4.8. Summary

Chapter 5. Effects of Tool Geometry

5.1. A Survey of Tool Effects in Friction Stir Welding

5.2. Tool Types and Geometries in Additive Friction Stir Deposition

5.3. Effects of Tool Geometry on Interface Morphology

5.4. Effects of Tool Geometry on Microstructure

5.5. Summary

Chapter 6. Beyond Metals and Alloys: Additive Friction Stir Deposition of Metal Matrix Composites

6.1. Introduction to Metal Matrix Composites

6.2. Current Processing Approaches to Metal Matrix Composites

6.3. Additive Friction Stir Deposition of Metal Matrix Composites

6.4. Examples

6.5. Limitations of this Printing Approach

6.6. Summary

Chapter 7. Mechanical Properties of the Printed Materials

7.1. Elements of Mechanical Behavior of Materials

7.2. Tensile Properties of the Printed Metals and Alloys

7.3. Fracture Behavior

7.4. Fatigue Behavior

7.5. Mechanical Properties of Bilayer Structures

7.6. Mechanical Properties of Printed Metal Matrix Composites

7.7. Summary

Chapter 8. Niche Applications

8.1. Structural Repair

8.2. Selective Area Cladding on Thin Substrates

8.3. Recycling

8.4. Large-Scale Additive Manufacturing

8.5. Printing and Repair under Harsh Conditions

8.6. Summary

Chapter 9. Future Perspectives

9.1. In-Depth Understanding of the Underlying Physics

9.2. Material Innovation

9.3. Incorporation of Artificial Intelligence

9.4. Summary

Review quotes

"Prof. Hang Yu has created a masterpiece in this first book on the additive friction stir deposition technology. Additive friction stir deposition is emerging as a very high deposit rate additive manufacturing process and has started finding real world applications. This book provides a timely overview of this new field. As researchers and practitioners of this new technology work on various new opportunities, they will benefit from the necessary theoretical basis provided in Chapters 2, 3, 4 and 7. Prof. Yu draws from his own research and experience to provide insights. It is a very comprehensive book that covers from process physics and materials science to tooling/applications. This is a great resource for students who get in this field and is a "must read"book. Faculty teaching advanced manufacturing processes can use several chapters to teach about this disruptive manufacturing process."—Dr. Rajiv Mishra, University Distinguished Professor, University of North Texas, USA

"A very timely book on this new emerging solid-state additive manufacturing technology. An excellent reference for those who are interested in  this dynamic and fast growth topic, from fundamentals of the process, technology innovations, and resulting microstructure and properties."—Dr. Zhili Feng, Distinguished R&D Staff, and Leader Materials Joining Group, Oak Ridge National Laboratory, USA

"Prof. Yu’s research has placed him and his team at the forefront of a technology that is seeing tremendous growth on the global additive manufacturing stage. This book expertly combines knowledge gained from years of experience into a single source that will offer the reader a keen insight into understanding the MELD process."—Dr. Chase Cox, Vice President, MELD Manufacturing Corporation, USA

"A thorough book on the emerging additive friction stir deposition technology that is poised to be very disruptive to fusion-based additive manufacturing. It sufficiently covers the benefits and challenges of using the process and provides a solid foundation for further research."—Dr. Michael Eller, Adjunct Professor, University of New Orleans, USA

Product details

  • Edition: 1
  • Latest edition
  • Published: July 19, 2022
  • Language: English

About the author

HY

Hang Z. Yu

Dr. Hang Z. Yu is an Associate Professor of Materials Science and Engineering at Virginia Tech. He received his bachelor’s degree in physics from Peking University in 2007 and his PhD degree in materials science and engineering from Massachusetts Institute of Technology in 2013. Prof. Yu is the recipient of DARPA (Defense Advanced Research Projects Agency) Young Faculty Award. At Virginia Tech, the primary interest of Prof. Yu’s research group lies in manufacturing science, with an emphasis on advanced materials processing and Industry 4.0. As a research pioneer of additive friction stir deposition, Prof. Yu is exploring multiple facets of the process, including integration of in situ monitoring and physics simulation for process control (temperature, force and torque, material flow, and distortion), design and synthesis of hybrid materials with innovative 3D internal structures, as well as use of the technology for structural repair, selective-area cladding, and materials recycling and upcycling.
Affiliations and expertise
Associate Professor of Materials Science and Engineering, Virginia Tech, USA

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