Synthesis of High Entropy Alloy for Surface Modification by Friction Stir Process: Recent Advances and Future Directions

The application of Metal Additive Manufacturing (MAM) in the aerospace industry has been gaining attention. The poor surface quality of parts greatly limits the prospects of MAM-produced parts in the aerospace industry as fatigue performance hinges on a good surface finish and homogeneous microstructure. Post-processing treatments are important to improve the surface quality and the overall performance of MAM-produced parts during static and dynamic loadings. This paper provides a review of the current state of post-processing treatment options for MAM-produced parts. The advances in the post-processing treatments of MAM parts to improve fatigue strength, tensile strength, surface integrity and other properties of parts are reviewed. Future research prospects on metal additive manufacturing of aerospace parts are briefly expounded. Abbreviations: AM: Additive Manufacturing; CMT-WAAM: Cold Metal Transfer-Based Wire Arc Additive Manufacturing; CSD: Cold Spray Deposition; DA: Direct Aging; DED: Directed Energy Deposition; E: Elongation; EBAM: Wire-feed Electron Beam Additive Manufacturing; EBAM Electron Beam Additive Manufacturing; EBSD: Electron Back Scattered Diffraction; FRAM: Friction Rolling Additive Manufacturing; FSAM: Friction Stir Additive Manufacturing; FSP: Friction Stir Processing; HFDB: Hybrid Friction Diffusion Bonding; HIP: Hot Isostatic Pressing; HSA Homogenisation + Solution Treatment + Aging; IFSP: Interlayer Friction Stir Processing; IPF: Inverse Pole Figure; KAM: Kernel Average Misorientation; LAM: Laser Additive Manufacturing Process; LENS: Laser Engineered Net Shaping; LDM: Laser Deposition Manufacturing; L-PBF: Laser Powder Bed Fusion; MAM: Metal Additive Manufacturing; MTFS: Multi-track Multi-layer Friction Surfacing; O-WLAM: Wire Oscillating Laser Additive Manufacturing (O-WLAM); S: Solution Treatment; SA: Solution Treatment + aging; TEM: Transmission Electron Microscope; UAM: Ultrasonic Additive Manufacturing; UTS: Ultimate Tensile Strength; WAAM: Wire Arc Additive Manufacturing; YS: Yield Strength

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: a review

Aluminum matrix surface composites (AMSCs) reinforced by various content of zirconium dioxide (ZrO2) nanoparticles and graphite (Gr) microparticles were fabricated by four passes of friction stir processing (FSP). Processing of composites reinforced by Gr particles did not lead to the sound and well-mixed composites due to a decline in the maximum experienced temperature during the process resulting from the low friction coefficient of graphite particles. Combination of graphite and zirconia particles resulted in a more homogenous dispersion of particles in the stir zone (SZ) due to a higher frictional heat generation and a lower tendency for agglomeration of nanoparticles as compared to relevant mono-composites. The occurrence of dynamic recovery (DRV) and dynamic recrystallization (DRX) along with particle stimulated nucleation (PSN) and pinning effect of the particles led to fine and equiaxed grains in the SZ as compared to coarse and elongated grains of the base metal. X-ray diffraction (XRD) analysis demonstrated formation of the Al3Zr intermetallic compounds in Al/ZrO2 nanocomposites because of in-situ reactions. Tensile tests and microhardness measurements showed that the ultimate tensile stress (UTS), yield stress (YS), and microhardness of composites gradually improved by an increase in the weight percent of the secondary phases. The UTS of Al/9 wt% ZrO2, Al/2 wt% Gr, and Al/3 wt% (Gr + ZrO2) with a hybrid ratio of (Gr/ZrO2 = 2) increased ∼42%, ∼53%, and ∼32% as compared to the base metal, respectively. Elongation of composites, especially in graphite-reinforced composites, decreased after FSP. The hybrid composite with a hybrid powder ratio of Gr/ZrO2 = 1 showed the lowest fluctuation of microhardness values because of a uniform particle distribution in the SZ. Hybrid composites with higher Gr content (Gr/ZrO2 = 2) showed greater UTS and microhardness values and lower elongation as compared to other hybrid composites. 

Microstructure and mechanical properties of al/graphite- zirconium oxide hybrid composite fabricated by friction stir processing

Microstructure and mechanical property evolution of in-situ ZrB2/AA7085 nanocomposites during hot rolling

Recent progress in high-entropy alloys for laser powder bed fusion: Design, processing, microstructure, and performance

In this work, Friction stir processing (FSP) was conducted on the CoCrFeMnNi alloy fabricated via laser powder bed fusion (LPBF) to modify the surface microstructure, during which the evolution of grain structures, dislocation structures, and texture as well as the dynamic recrystallization (DRX) mechanism were investigated. The experimental results demonstrated that continuous dynamic recrystallization (CDRX) and discontinuous dynamic recrystallization (DDRX) occurred simultaneously to refine the average grain size from 15.4 μm to 4.8 μm, while the distribution of grain size and area became more uniform in the stir zone (SZ). Due to the inhomogeneous distribution of material flow and friction heat, the thermo-mechanically affected zone (TMAZ) exhibits microstructure gradients and the grain structures are nonuniform throughout the SZ. In addition, the relationship between the microstructure and mechanical properties of the FSP region was analyzed. The hardness and yield strength (YS) of the SZ (∼190 ± 3 HV and 501 ± 2 MPa, respectively) are lower than those of the LPBF material (∼229 ± 10 HV and 563 ± 3 MPa, respectively). On the other hand, the elongation increased from 23.8 ± 0.4% to 37.5 ± 0.3%, while the ultimate tensile strength (UTS) increased from 665 ± 5 MPa to 719 ± 3 MPa. A better combination of strength and ductility than the LPBF-built CoCrFeMnNi alloy was achieved in the SZ after FSP. 

Microstructure transition and mechanical properties of friction stir processed CoCrFeMnNi high entropy alloy fabricated by laser powder bed fusion

Sulfolobus acidocaldarius microvesicles are naturally occurring nanoparticles with unusual stability against various environmental stressors

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Microstructure transition and mechanical properties of friction stir processed CoCrFeMnNi high entropy alloy fabricated by laser powder bed fusion

Sulfolobus acidocaldarius microvesicles are naturally occurring nanoparticles with unusual stability against various environmental stressors