Review:Friction Stir Processing - A Sustainable Technique for the Fabrication of Aluminum Surface Composites

IF 3.9 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Materials Science Pub Date : 2025-09-12 DOI:10.1007/s10853-025-11480-7

Shazman Nabi, Sandeep Rathee, Mohammad Farooq Wani

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Abstract

Friction stir processing (FSP) has established itself as a transformative solid-state technique for enhancing the surface properties of metals and alloys, particularly aluminum alloys, through microstructural refinement and reinforcement incorporation. Over the past 25 years, extensive research has focused on developing aluminum surface composites (ASCs) via FSP, leading to significant improvements in mechanical strength, wear resistance, and corrosion performance. This review provides a comprehensive overview of FSP, tracing its historical development, fundamental principles, and the influence of key process parameters such as tool geometry, rotational speed, traverse speed, and processing strategies. A diverse range of reinforcement materials—including ceramics, metal oxides, and hybrid particles—has been employed to tailor the functional properties of ASCs. The review also highlights persistent challenges, including the uniform distribution of reinforcements, optimization of mechanical behavior, and the scalability of FSP for industrial applications. Furthermore, emerging directions such as hybrid reinforcement design, in situ process monitoring, and the integration of FSP with additive manufacturing are discussed, offering a roadmap for future advancements.

Graphical abstract

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综述：搅拌摩擦加工-一种可持续的铝表面复合材料制造技术

摩擦搅拌加工（FSP）已经确立了自己作为一种变革性的固态技术，通过显微组织的细化和增强加入来提高金属和合金，特别是铝合金的表面性能。在过去的25年里，广泛的研究集中在通过FSP开发铝表面复合材料（ASCs）上，导致机械强度，耐磨性和腐蚀性能的显着提高。这篇综述提供了FSP的全面概述，追溯其历史发展，基本原理，以及关键工艺参数，如刀具几何形状，转速，遍历速度和加工策略的影响。各种增强材料（包括陶瓷、金属氧化物和混合颗粒）已被用于定制ASCs的功能特性。该综述还强调了持续存在的挑战，包括增强材料的均匀分布、机械性能的优化以及FSP在工业应用中的可扩展性。此外，本文还讨论了混合增强设计、现场过程监控以及FSP与增材制造的集成等新兴方向，为未来的发展提供了路线图。图形抽象

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来源期刊

Journal of Materials Science 工程技术-材料科学：综合

CiteScore

7.90

自引率

4.40%

发文量

1297

审稿时长

2.4 months

期刊介绍： The Journal of Materials Science publishes reviews, full-length papers, and short Communications recording original research results on, or techniques for studying the relationship between structure, properties, and uses of materials. The subjects are seen from international and interdisciplinary perspectives covering areas including metals, ceramics, glasses, polymers, electrical materials, composite materials, fibers, nanostructured materials, nanocomposites, and biological and biomedical materials. The Journal of Materials Science is now firmly established as the leading source of primary communication for scientists investigating the structure and properties of all engineering materials.