Friction Stir Processing for Enhanced Low Temperature Formability

Friction Stir Processing for Enhanced Low Temperature Formability

A volume in the Friction Stir Welding and Processing Book Series

1st Edition - March 21, 2014

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  • Authors: Christopher Smith, Rajiv Mishra
  • eBook ISBN: 9780124201835
  • Paperback ISBN: 9780124201132

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The use of friction stir processing to locally modify the microstructure to enhanced formability has the potential to alter the manufacturing of structural shapes. There is enough research to put together a short monograph detailing the fundamentals and key findings. One example of conventional manufacturing technique for aluminum alloys involves fusion welding of 5XXX series alloys. This can be replaced by friction stir welding, friction stir processing and forming. A major advantage of this switch is the enhanced properties. However qualification of any new process involves a series of tests to prove that material properties of interest in the friction stir welded or processed regions meet or exceed those of the fusion welded region (conventional approach). This book will provide a case study of Al5083 alloy with some additional examples of high strength aluminum alloys.

Key Features

  • Demonstrates how friction stir processing enabled forming can expand the design space by using thick sheet/plate for applications where pieces are joined because of lack of formability
  • Opens up new method for manufacturing of structural shapes
  • Shows how the process has the potential to lower the cost of a finished structure and enhance the design allowables


Researchers, design engineers, materials processing engineers, welding engineers and students

Table of Contents

  • Chapter 1. Concept of Friction Stir Processing for Enhanced Formability

    • 1.1 Background

    Chapter 2. Fundamentals of Formability

    • 2.1 Introduction
    • 2.2 Tensile Test and Formability

    Chapter 3. High Structural Efficiency Design Potentials with Enhanced Formability

    • 3.1 Background
    • 3.2 Fabrication Processes
    • 3.3 Summary

    Chapter 4. Case Study of Aluminum 5083-H116 Alloy

    • 4.1 Case Study Initiation
    • 4.2 Initial Feasibility Results
    • 4.3 Case Study Description
    • 4.4 Initial Comparative Process Qualification
    • 4.5 GMAW Qualification and Destructive Testing
    • 4.6 FSP Qualification and Destructive Testing
    • 4.7 FSW Initial Qualification and Destructive Testing
    • 4.8 Macro Cross Section Comparison
    • 4.9 Microhardness Test Results and Comparison
    • 4.10 Macro Transverse Tensile Test Results
    • 4.11 Young’s and Shear Modulus Test Results
    • 4.12 Mini Transverse Tensile Test Results
    • 4.13 Mini Longitudinal Tensile Test Results
    • 4.14 Distortion Measurements
    • 4.15 Corrosion Testing
    • 4.16 Fatigue Testing
    • 4.17 Corrosion Fatigue Testing

    Chapter 5. Examples of Enhanced Formability of High-Strength Aluminum Alloys

    • 5.1 Background
    • 5.2 Examples of Enhanced Formability of High-Strength Aluminum Alloys
    • 5.3 Summary

Product details

  • No. of pages: 148
  • Language: English
  • Copyright: © Butterworth-Heinemann 2014
  • Published: March 21, 2014
  • Imprint: Butterworth-Heinemann
  • eBook ISBN: 9780124201835
  • Paperback ISBN: 9780124201132

About the Authors

Christopher Smith

Christopher Smith
Mr. Smith is a Project Manager at Wolf Robotics in Fort Collins, Colorado, specializing in projects advancing the state of the capability automatic robotic solutions and has been with Wolf Robotics since early 2013. Prior to that, Chris was Co-Founder and Vice President of Engineering of Friction Stir Link, Inc. (FSL) in Brookfield, WI which was founded in 2001. At FSL, Chris led efforts in the commercialization of friction stir welding and the related technologies. Prior to FSL, Chris began his career at A.O. Smith Automotive Products Company, where he was responsible for the development of new robotic processing technologies. Throughout his career, Mr. Smith has lead the development and integration of new automated technologies and has been involved with friction stir welding, arc welding, machining and material handling technologies. He developed the first production capable industrial robotic system for friction stir welding. Chris has managed projects leading to significant advancements in robotic material handling, friction stir welding and its related technologies, as well as robotic machining and drilling. At FSL he managed projects leading to many of North America’s first and/or most significant friction stir welding applications. Mr. Smith has a Bachelor of Science Degree from the University of Colorado-Boulder and Master of Science degree from the University of Wisconsin-Madison in Mechanical Engineering. He was awarded the American Welding Society’s A.F. Davis Silver Medal Award in 2001. Chris has authored over 30 papers and chapters on FSW in two engineering books and has two patents. Chris also is co-chair of the American Welding Society’s C6 Committee on Recommended Practices for Friction Stir Welding.

Affiliations and Expertise

Project Manager, Wolf Robotics, Fort Collins, Colorado

Rajiv Mishra

Rajiv Mishra
Rajiv S. Mishra is a professor in the Department of Materials Science and Engineering, and Site Director, NSF IUCRC for Friction Stir Processing, at the University of North Texas. Dr. Mishra’s publication record includes 255 papers. Out of these, 10 of his papers have more than 100 citations. He has many ‘firsts’ in the field of friction stir welding and processing. He co-authored the first review paper (2005), co-edited the first book on the subject (2007), edited/co-edited seven TMS symposium proceedings, and served as guest editor for Viewpoint Set in Scripta Materialia (2008). He also has three patents in this field. He published the first paper on friction stir processing (2000) as a microstructural modification tool.

Affiliations and Expertise

Professor, Department of Materials Science and Engineering, Site Director, NSF IUCRC, University of North Texas, USA

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