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El. knyga: Additive Friction Stir Deposition

(Associate Professor of Materials Science and Engineering, Virginia Tech, USA)
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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.

  • 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

Recenzijos

"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. Yus 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

Preface xi
Book endorsement: Additive Friction Stir Deposition xv
1 Introduction
1(20)
1.1 Additive manufacturing for metals
2(3)
1.2 Solid-state metal additive manufacturing
5(4)
1.3 Additive friction stir deposition
9(7)
1.4 Organization of this book
16(5)
References
18(3)
2 Process fundamentals
21(56)
2.1 Elements of friction theory
22(7)
2.2 Fundamentals of heat and mass transfer
29(4)
2.2.1 Heat transfer
29(2)
2.2.2 Mass transfer
31(2)
2.3 Basic principle of additive friction stir deposition
33(4)
2.4 Establishment of an integrated in situ monitoring system: real-time measurement of temperature, force, torque, and material flow
37(4)
2.5 Temperature evolution in the deposited material and substrate
41(10)
2.5.1 Thermal history of the deposited materials
41(2)
2.5.2 Dependence of thermal features on the processing conditions in additive friction stir deposition
43(4)
2.5.3 Power law relationships of peak temperature and processing parameters
47(1)
2.5.4 Temperature evolution of the substrate
48(3)
2.6 Force and torque evolution
51(6)
2.6.1 Multiple phases of force and torque evolution
52(2)
2.6.2 Dependence of steady-state force and torque on processing conditions
54(3)
2.7 In situ visualization of material rotation and flow
57(7)
2.7.1 Footprint and material rotation
58(2)
2.7.2 Contact state and sticking coefficient
60(4)
2.8 Correlation of the material flow behavior to temperature, force, and torque evolution
64(9)
2.8.1 Influences of the contact state and material flow on heat generation
66(3)
2.8.2 Influences of the contact state and material flow on force and torque
69(2)
2.8.3 Factors governing the contact state and material flow behavior
71(2)
2.9 Summary
73(4)
References
74(3)
3 Material flow phenomena
77(50)
3.1 Plasticity and finite deformation theory
78(4)
3.2 Elements of fluid mechanics
82(5)
3.3 Previous experimental studies on material flow in friction stir welding
87(5)
3.4 Design of tracer experiments for material flow investigation in additive friction stir deposition
92(3)
3.5 Flow path of the center volume of the feed material
95(12)
3.5.1 Center tracer flow during initial material feeding
95(7)
3.5.2 Center tracer flow during steady-state deposition
102(5)
3.6 Flow path of the edge volume of the feed material
107(5)
3.6.1 Edge tracer flow during initial material feeding
107(3)
3.6.2 Edge tracer flow during steady-state deposition
110(2)
3.7 Material deformation and flow at the interface
112(10)
3.7.1 Surface and interface morphology
113(5)
3.7.2 Interfacial mixing
118(4)
3.8 Summary
122(5)
References
124(3)
4 Dynamic microstructure evolution
127(56)
4.1 Elements of microstructure evolution
129(6)
4.2 Dynamic recrystallization mechanisms
135(7)
4.2.1 Discontinuous dynamic recrystallization
135(3)
4.2.2 Continuous dynamic recrystallization
138(4)
4.3 Thermomechanical history in additive friction stir deposition
142(5)
4.3.1 Stage A
143(1)
4.3.2 Stage B
144(2)
4.3.3 Stage C
146(1)
4.4 Characteristics of the resulting microstructures by additive friction stir deposition
147(4)
4.4.1 High stacking fault energy materials: Al and Mg
147(2)
4.4.2 Low (to medium) stacking fault energy materials: Inconel 625 and 316 L stainless steel
149(2)
4.5 Dynamic microstructure evolution along the flow path of an Al-Cu alloy
151(10)
4.5.1 Microstructure characterization along the flow path of the center tracer
151(5)
4.5.2 Microstructure characterization along the flow path of the edge tracer
156(2)
4.5.3 Quantification of the overall trend
158(3)
4.6 Processing-microstructure linkages of Al-Mg-Si and Cu
161(13)
4.6.1 Microstructure characterization of Al--Mg--Si printed at various conditions
162(5)
4.6.2 Microstructure characterization of Cu printed at various conditions
167(3)
4.6.3 Analysis of the microstructure evolution mechanisms and trends
170(4)
4.7 Dynamic phase evolution
174(2)
4.8 Summary
176(7)
References
178(5)
5 Effects of tool geometry
183(20)
5.1 A survey of tool effects in friction stir welding
184(2)
5.2 Tool types and geometries for additive friction stir deposition
186(3)
5.3 Effects of tool geometry on interface morphology
189(7)
5.4 Effects of tool geometry on microstructure
196(4)
5.5 Summary
200(3)
References
200(3)
6 Beyond metals and alloys: additive friction stir deposition of metal matrix composites
203(30)
6.1 Introduction to metal matrix composites
204(2)
6.2 Current processing approaches to metal matrix composites
206(9)
6.2.1 Bulk processing
206(4)
6.2.2 Additive production
210(5)
6.3 Additive friction stir deposition of metal matrix composites
215(4)
6.3.1 Feeding strategy and printing principle
216(1)
6.3.2 Potential benefits
217(2)
6.4 Examples
219(8)
6.4.1 Cu-Zr02 printed using a composite feed-rod
219(1)
6.4.2 Al-Zr02, Al-SiC, and Cu-SiC composites printed by packing particles in the hollow feed-rod
219(6)
6.4.3 Al--SiC printed by auger feeding
225(2)
6.5 Limitations of this printing approach
227(2)
6.5.1 Maximum volume fraction of reinforcement
227(1)
6.5.2 Tool wear
228(1)
6.6 Summary
229(4)
References
230(3)
7 Mechanical properties of the printed materials
233(44)
7.1 Elements of the mechanical behavior of materials
234(4)
7.2 Tensile properties of the printed metals and alloys
238(18)
7.2.1 Effects of precipitation strengthening
238(6)
7.2.2 Effects of postprocess aging
244(2)
7.2.3 Effects of dislocation content
246(4)
7.2.4 Effects of grain size
250(3)
7.2.5 Two-phase alloys
253(1)
7.2.6 Gradient of the mechanical properties
254(2)
7.3 Fracture behavior
256(8)
7.4 Fatigue behavior
264(4)
7.5 Mechanical properties of bilayer structures
268(3)
7.6 Mechanical properties of printed metal matrix composites
271(1)
7.7 Summary
271(6)
References
272(5)
8 Niche applications
277(42)
8.1 Structural repair
278(14)
8.1.1 Through-hole filling
281(3)
8.1.2 Groove filling
284(2)
8.1.3 Surface and divot repair
286(3)
8.1.4 Fastener hole repair
289(3)
8.2 Selective-area cladding on thin automotive sheet metals
292(9)
8.2.1 Cladding quality
292(3)
8.2.2 Thin substrate distortion
295(6)
8.3 Recycling
301(9)
8.3.1 Solid-state metal recycling background
301(4)
8.3.2 Friction stirring for solid-state recycling
305(5)
8.4 Large-scale additive manufacturing
310(1)
8.5 Printing and repair under harsh conditions
311(2)
8.6 Summary
313(6)
References
314(5)
9 Future perspectives
319(8)
9.1 In-depth understanding of the underlying physics
320(1)
9.2 Material innovation
321(1)
9.3 Incorporation of artificial intelligence
322(3)
9.4 Summary
325(2)
References
325(2)
Index 327
Dr. Hang Z. Yu is an Associate Professor of Materials Science and Engineering at Virginia Tech. He received his bachelors 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. Yus 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.
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