Friction Stir Welding and Processing (Materials Forming, Machining and Tribology)

Preface
Contents
Abbreviations
1 Friction Stir Welding and Processing
	1.1 Friction Stir Welding
	1.2 Friction Stir Processing
	1.3 Deformation-Driven Metallurgy
	References
2 Self-Supported Friction Stir Welding
	2.1 Introduction
	2.2 Bobbin Tool Friction Stir Welding
		2.2.1 Principle
		2.2.2 Technical Development
		2.2.3 Formation Mechanism
		2.2.4 Microstructural Characteristics
		2.2.5 Mechanical Properties
		2.2.6 Prospects
	2.3 Penetrating Friction Stir Welding
		2.3.1 Principle
		2.3.2 Joint Formation
		2.3.3 Mechanical Properties
		2.3.4 Prospects
	2.4 Self-Support Friction Stir Welding
		2.4.1 Principle
		2.4.2 Design Criterion of Welding Tools
		2.4.3 Formation Mechanism
		2.4.4 Microstructural Characteristics
		2.4.5 Second-Phase Particles and Grain Morphology
	2.5 Plastic Deformation Analysis of SSFSW1 Joint
	2.6 Prospects
	References
3 Non-weld-Thinning Friction Stir Welding
	3.1 Stationary Shoulder Friction Stir Welding
		3.1.1 Principle
		3.1.2 Welding Tools
		3.1.3 Material Compatibilities
		3.1.4 Microstructural Characteristics
		3.1.5 Process Development
		3.1.6 Mechanical Properties
		3.1.7 Prospects
	3.2 Additive Friction Stir Welding
		3.2.1 Friction Stir Welding
		3.2.2 Compensation Friction Stir Welding
	3.3 Zero-Plunge-Depth Friction Stir Welding
		3.3.1 Principle
		3.3.2 Formation Mechanism
		3.3.3 Microstructural Characteristics
		3.3.4 Mechanical Properties
		3.3.5 Corrosion Behaviour
		3.3.6 Prospects
	References
4 Friction Stir-Based Remanufacturing
	4.1 Background
	4.2 Principle and Advantages
	4.3 Types of FSW Defects
	4.4 Repetitive Friction Stir Remanufacturing
	4.5 Additive Friction Stir Remanufacturing
		4.5.1 Friction Plug Welding
		4.5.2 Friction Taper Plug Welding
		4.5.3 Progressive Friction Stir Welding
		4.5.4 Refill Friction Stir Spot Welding
		4.5.5 Filling Friction Stir Welding
	4.6 Prospects
	References
5 High Depth-to-Width Ratio Friction Stir Welding
	5.1 Numerical Design of High Depth-to-Width Ratio Friction Stir Welding
		5.1.1 Introduction
		5.1.2 Experimental Procedures
		5.1.3 Numerical Modeling
		5.1.4 Temperature Distribution and Validation
		5.1.5 Fracture Criteria
		5.1.6 Defect Prediction
		5.1.7 High-Throughput Screening
		5.1.8 Joint Formation
		5.1.9 Summary
	5.2 Joint Formation Mechanism of High Depth-to-Width Ratio Friction Stir Welding
		5.2.1 Introduction
		5.2.2 Experimental Procedures
		5.2.3 Numerical Modeling
		5.2.4 Joint Formation
		5.2.5 Numerical Evaluation
		5.2.6 Fractrography
		5.2.7 Mechanical Properties
		5.2.8 Summary
	5.3 Grain Growth Behavior of High Depth-to-Width Ratio Friction Stir Welding
		5.3.1 Introduction
		5.3.2 Experimental Procedures
		5.3.3 Numerical Modeling
		5.3.4 Microstructural Factors
		5.3.5 Precipitation Transformation
		5.3.6 Dynamic Recrystallization and Pinning Effect
		5.3.7 Summary
	References
6 Entire-Process Simulation of Friction Stir Welding
	6.1 Experiments and Simulation
		6.1.1 Introduction
		6.1.2 Experimental Procedures
		6.1.3 Finite Element Modeling
		6.1.4 Precipitation Evolution Modeling
		6.1.5 Dynamic Recrystallization Modeling
		6.1.6 Strengthening Modeling
		6.1.7 Tensile Behavior Modeling
		6.1.8 Causative Variables and Experimental Validations
		6.1.9 Microstructural Evolutions
		6.1.10 Summary
	6.2 Implementation of Neural Networks
		6.2.1 Introduction
		6.2.2 Methodology
		6.2.3 Implementation Evaluation
		6.2.4 Summary
	References
7 Surface Modification via Friction Stir Processing
	7.1 Surface Composite Fabricated by Direct Friction Stir Processing
		7.1.1 Introduction
		7.1.2 Materials and Experimental Procedure
		7.1.3 Microstructure
		7.1.4 Micro-hardness and Surface Wear Properties
		7.1.5 Summary
	7.2 Cryogenic Surface-Grinding Assisted Friction Stir Processing
		7.2.1 Introduction
		7.2.2 Materials and Experimental Procedure
		7.2.3 Microstructure Evolution and Properties
		7.2.4 Grain Refinement Modes
		7.2.5 Summary
	7.3 Arc Surface-Nitriding Assisted Friction Stir Processing
		7.3.1 Introduction
		7.3.2 Materials and Experimental Procedure
		7.3.3 Microstructure of Nitriding Coating
		7.3.4 Microstructure of the Functionally Gradient Coating
		7.3.5 Microhardness
		7.3.6 Scratch Property
		7.3.7 Wear Property
		7.3.8 Summary
	References
8 Friction Stir Processed Bulk Materials
	8.1 Microstructural Evolution and Mechanical Properties of Mg–Zn–Y–Zr Alloy During Friction Stir Processing
		8.1.1 Introduction
		8.1.2 Experimental Procedures
		8.1.3 Grain Refinement
		8.1.4 Transformation of the Second Phases
		8.1.5 Texture Evolution Analysis
		8.1.6 Tensile Properties and Fractography
		8.1.7 Relationship Between Microstructure Evolution and FSP Parameters
		8.1.8 Transformation of the Second Phase in Mg–Zn–Y–Zr System
		8.1.9 Strengthening Mechanism of Mg–Zn–Y–Zr Material
		8.1.10 Toughening Mechanism of Mg–Zn–Y–Zr Material
		8.1.11 Fracture Behavior
		8.1.12 Summary
	8.2 Dynamic Recrystallization and Mechanical Properties of Friction Stir Processed Mg–Zn–Y–Zr Alloys
		8.2.1 Introduction
		8.2.2 Experimental Procedure
		8.2.3 Grain Refinement Process
		8.2.4 Characterization of the Second Phase
		8.2.5 Mechanical Properties
		8.2.6 Fracture Behavior Analysis
		8.2.7 Summary
	8.3 Ultrafine-Grained Mg–Zn–Y–Zr Alloy with Remarkable Improvement in Superplasticity
		8.3.1 Introduction
		8.3.2 Experimental Procedures
		8.3.3 Microstructures Characteristics Analysis of the FSPed Mg–RE Alloys
		8.3.4 Superplasticity Behavior Analysis of the FSPed Mg–RE Alloys
	8.4 Enhanced Strength and Ductility of Friction-Stir-Processed Mg–6Zn Alloys via Y and Zr Co-Alloying
		8.4.1 Introduction
		8.4.2 Materials and Experimental Procedure
		8.4.3 Microstructures of the Mg–6Zn–(1Y–0.5Zr) Alloys
		8.4.4 Mechanical Properties of the Mg–6Zn–(1Y–0.5Zr) Alloys
		8.4.5 Effect of Co-alloying on Microstructural Evolution
		8.4.6 Evaluation and Modelling of Mechanical Properties Enhancement
		8.4.7 Summary
	8.5 Strengthening and Toughening Mechanisms of CNTs/Mg–6Zn Composites via Friction Stir Processing
		8.5.1 Introduction
		8.5.2 Experimental Procedures
		8.5.3 Microstructure Characterization
		8.5.4 Morphology, Distribution and Integrity of CNTs
		8.5.5 Mechanical Properties
		8.5.6 Fracture Behaviors
		8.5.7 Strengthening Mechanisms
		8.5.8 Summary
	References
9 Graphene Nanoplatelet-Reinforced Aluminum Matrix Composites
	9.1 Feasibility Verification of Deformation-Driven Metallurgy
		9.1.1 Introduction
		9.1.2 Experimental Procedures
		9.1.3 Coupled Thermal-Flow Modeling
		9.1.4 Microstructural Characteristics
		9.1.5 Mechanical Properties
		9.1.6 Strengthening Modes
		9.1.7 Summary
	9.2 Ameliorating Strength-Ductility Efficiency of Graphene Nanoplatelet-Reinforced Aluminum Composites
		9.2.1 Introduction
		9.2.2 Experimental Procedures
		9.2.3 Arbitrary Lagrange-Euler Modeling
		9.2.4 Characterization of the Powders and the Composites
		9.2.5 Microstuctural Characteristics
		9.2.6 Mechanical Performances
		9.2.7 Summary
	9.3 Grain Refinement Mechanisms of Graphene Nanoplatelet-Reinforced Aluminum Composites
		9.3.1 Introduction
		9.3.2 Experimental Procedures
		9.3.3 Grain Refinement Mechanisms
		9.3.4 Summary
	References
10 Anti-corrosion Aluminum Matrix Composites
	10.1 Homogeneously Dispersed Graphene Nanoplatelets as Corrosion Inhibitors
		10.1.1 Introduction
		10.1.2 Experimental Procedures
		10.1.3 Density Functional Theory Calculation
		10.1.4 Microstructural Characteristics
		10.1.5 Corrosion Behaviors
		10.1.6 Long-Term Corrosion Inhibitor Evaluation
		10.1.7 Summary
	10.2 Heteroatom Modification Towards Enhanced Corrosion Resistance
		10.2.1 Introduction
		10.2.2 Experimental Procedures
		10.2.3 Density Functional Theory Calculation
		10.2.4 Microstructural Factors
		10.2.5 Mechanical Performances
		10.2.6 Electrochemical Corrosion Behaviors
		10.2.7 Corrosion Suppression Activity
		10.2.8 Summary
	References
11 SiC Reinforced Aluminum Matrix Composites via Deformation-Driven Metallurgy
	11.1 Effect of the SiC Particle Size on the Strength-Ductility Synergy of the Reinforced Aluminum Matrix Composites
		11.1.1 Introduction
		11.1.2 Experimental Procedures
		11.1.3 Microstructural Integrity
		11.1.4 Dynamic Recrystallization Process
		11.1.5 Strengthening Mechanism
		11.1.6 Summary
	11.2 Nano-SiC Particles Reinforced Aluminum Matrix Composites via Optimized Mass Fraction
		11.2.1 Introduction
		11.2.2 Experimental Procedures
		11.2.3 Microstructures
		11.2.4 Mechanical Properties
		11.2.5 Principle of DDM
		11.2.6 Strengthening Behaviors
		11.2.7 Summary
	References