Progresses in multi-materials billet manufacturing out of metal scraps through friction stir consolidation

Progresses in multi-materials billet manufacturing out of metal scraps through friction stir consolidation

Abdul Latif, Giuseppe Ingarao, Livan Fratini, Fabrizio Micari

Abstract. The evolution of Friction Stir Consolidation (FSC) from recycling towards upcycling technique proved to be one of the excellent solid-state methods for manufacturing functionally graded billets. Multi-material Functional Graded Materials (FGMs) represent a novel class of materials characterized by a gradual change in properties and functions which can be tailored to enhance components performance. Manufacturing techniques play a critical role in achieving the designed compositional and microstructural distribution. Specifically, FSC allows the manufacturing of FGM billets out of metallic chips; the mixing of different metallic chips offers mutually exclusive mechanical properties like high hardness and good ductility in a single FSC billet with excellent formability. The present research further explores some challenges while combining dissimilar aluminum alloys chips in different percentages and spatial order, especially in the radial direction. The mechanical and metallurgical properties were assessed through the Vickers hardness measurements and microstructure analysis. The results revealed that new strategies are needed for a better exploitation of FSC as a solid-state method for fabrication of Functionally Graded Material.

Keywords
Friction Stir Consolidation, Solid State Technique, Recycling and Upcycling, Functionally Graded Material, Aluminum Alloys

Published online 3/17/2022, 6 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: Abdul Latif, Giuseppe Ingarao, Livan Fratini, Fabrizio Micari, Progresses in multi-materials billet manufacturing out of metal scraps through friction stir consolidation, Materials Research Proceedings, Vol. 26, pp 713-718, 2023

DOI: https://doi.org/10.21741/9781644902431-114

The article was published as article 114 of the book Theoretical and Applied Mechanics

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] T.G. Gutowski, S. Sahni, J.M. Allwood, M.F. Ashby, E. Worrell, The energy required to produce materials: constraints on energy-intensity improvements, parameters of demand, Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences 371.1986 (2013): 20120003. https://doi.org/10.1098/rsta.2012.0003
[2] D. Raabe et al., Making sustainable aluminum by recycling scrap: The science of “dirty” alloys, Progress in Materials Science. (2022): 100947. https://doi.org/10.1016/j.pmatsci.2022.100947
[3] B. Wan, W. Chen, T. Lu, F. Liu, Z. Jiang, M. Mao, Review of solid state recycling of aluminum chips, Resources, Conservation and Recycling.125 (2017):37-47. https://doi.org/10.1016/j.resconrec.2017.06.004
[4] J.R. Duflou, A.E. Tekkaya, M. Haase, T. Welo, K. Vanmeensel, K Kellens, W Dewulf, D. Paraskevas, Environmental assessment of solid state recycling routes for aluminium alloys: can solid state processes significantly reduce the environmental impact of aluminium recycling?. CIRP Annals (2015) 64(1) pp 37-40. https://doi.org/10.1016/j.cirp.2015.04.051
[5] J.H. Bae, A.P. Rao, K.H. Kim, N.J. Kim, Cladding of Mg alloy with Al by twin-roll casting Scripta Materialia (2011) 64(9) pp 836-9. https://doi.org/10.1016/j.scriptamat.2011.01.013
[6] C. Zhang, F. Chen, Z. Huang, M. Jia, G. Chen, Y. Ye, E.J. Lavernia, Additive manufacturing of functionally graded materials: a review Materials Science and Engineering A (2019) 764 p 138209. https://doi.org/10.1016/j.msea.2019.138209
[7] A. Latif, G. Ingarao, L. Fratini, Multi-material based Functionally Graded billets manufacturing through Friction Stir Consolidation of aluminum alloys chips CIRP ANNALS, in press (2022). https://doi.org/10.1016/j.cirp.2022.03.035
[8] J.M. Allwood, J.M. Cullen, M.A. Carruth, D.R. Cooper, M. McBrien, R.L. Milford, M.C. Moynihan, A.C. Patel, Sustainable materials: with both eyes open, Vol. 2012, Cambridge, UK: UIT Cambridge Limited, 2012.