About the Editors xv
List of Contributors xviii
Preface xxv
Acknowledgements xxix
List of Figures xxx
List of Tables xl
1 Friction Stir Welding: An Overview 1
Farooz A. Najar, Shazman Nabi, Sandeep Rathee, and Manu Srivastava
1.1 Introduction 1
1.2 FSW Working Principle 2
1.3 Weld Zones 3
1.4 Variants of FSW 4
1.5 Defects 10
1.6 Advantages and Limitations of FSW 11
1.7 Conclusion and Future Prospectus 12
Acknowledgments 12
References 12
2 Friction Stir Welding and Single-Point Incremental Forming: State-of-the-Art 15
Hitesh Mhatre, Amrut Mulay, and Vijay Gadakh
2.1 Introduction 15
2.2 Friction Stir Welding (FSW) 16
2.3 Single-Point Incremental Forming (SPIF) 18
2.4 FSW and SPIF 21
2.5 Summary and Outlook 22
References 23
3 Friction Stir Brazing and Friction Stir Vibration Brazing 25
Behrouz Bagheri and Mahmoud Abbasi
3.1 Introduction to FSB 25
3.2 Variants of FSB 26
3.3 Two Case studies 27
3.4 Application of FSB and Its Variants in Industry 35
3.5 Summary and Future Directions 35
References 36
4 Fundamentals of Friction Stir Processing 39
Atul Kumar, Devasri Fuloria, Manu Srivastava, and Sandeep Rathee
4.1 Friction Stir Processing (FSP): Background 39
4.2 Working Principle of FSP 39
4.3 Comparison with Other Severe Plastic Deformation (SPD) Techniques 42
4.4 Process Variables 43
4.5 Mechanisms of Microstructural Evolution During FSP 48
4.6 Critical Issues in FSP 49
4.7 Future Scope 50
References 51
5 Role of FSP in Surface Engineering 55
Setu Suman and Kazi Sabiruddin
5.1 Introduction 55
5.2 Role of Surface Modification Techniques 56
5.3 Thermal Spray Technique 57
5.4 FSP - Solid-State Coating Process 58
5.5 Process Parameters of FSP: Surface Engineering 60
5.6 Inappropriate Characteristics of Surface Modification 61
5.7 Summary 63
References 64
6 Surface Composite Fabrication Using FSP 67
Baidehish Sahoo, Jinu Paul, and Abhishek Sharma
6.1 Introduction 67
6.2 Reinforcement Incorporation Approaches 68
6.3 Effect of Process Parameters 71
6.4 Microstructural Evolution and Mechanical Properties 75
6.5 Strengthening Mechanisms 80
6.6 Defects 83
6.7 Summary and Future Directions 86
References 86
7 Friction Stir Welding of Dissimilar Metals 93
Narayan Sahadu Khemnar, Yogesh Ramrao Gunjal, Vijay Shivaji Gadakh, and Amrut Shrikant Mulay
7.1 Introduction 93
7.2 Application Areas of Dissimilar Material Joining 94
7.3 Issues for Dissimilar Material Joining 94
7.4 FSW of Dissimilar Materials 95
7.5 Recent Developments in Tool Design and Tool Materials 103
7.6 Parameter Optimization 103
7.7 Common Defects that Occur in FSW of Dissimilar Metal Joining 104
7.8 Future Recommendations for Dissimilar Metal Joining 105
Acknowledgments 105
References 106
8 Friction Stir Welding of Aluminum and Its Alloy 109
Palani Sivaprakasam, Kolar Deepak, Durairaj Raja Joseph, Melaku Desta, Putti Venkata Siva Teja, and Murugan Srinivasan
8.1 Introduction 109
8.2 Fundamentals of FSW 110
8.3 FSW of Aluminum and Its Alloy 110
8.4 Influences of Process Parameters 112
8.5 Testing and Characterization of FSW of Al and Its Alloy 115
8.6 Additive Mixed Friction Stir Process of Al and Its Alloy 118
8.7 Applications 118
8.8 Conclusions 119
References 119
9 Mechanical Characterization of FSWed Joints of Dissimilar Aluminum Alloys of AA 7050 and AA6082 125
