Process mechanics in continuous friction stir extrusion process of aluminum alloy
Gianluca Buffa, Davide Campanella, Livan Fratini, Adnan Muhuammed, Fabrizio Micaridownload PDF
Abstract. Friction Stir Extrusion (FSE) is an innovative direct-recycling technology developed for metal machining chips. A rotating die is plunged into a cylindrical chamber containing the material to be recycled during the procedure. The die’s stirring action causes strong bonding, enabling for the back extrusion of a full dense rod. One of the technology’s major flaws is the process’ discontinuity, which limits the volume of extrudes to the chamber’s capacity. Based on the previous experience of some of the authors have designed a machine tool for continuous solid-state recycling of metal chips with the aims to overcome the limitations of the discontinuous process which makes it potentially appealing to industry. In this work, Friction Stir Extrusion process is defined, the set-up machines tool is presented, and the experimental findings of case studies are shown and analyzed. Finally, with the goal the mechanics of the FSE continuous process, a numerical model was created starting from the experimental results obtained by discontinuous process.
Recycling, Metals, Friction Stir Extrusion
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: Gianluca Buffa, Davide Campanella, Livan Fratini, Adnan Muhuammed, Fabrizio Micari, Process mechanics in continuous friction stir extrusion process of aluminum alloy, Materials Research Proceedings, Vol. 26, pp 719-724, 2023
The article was published as article 115 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.
 Gutowski, T. G., Sahni, S., Allwood, J. M., Ashby, M. F., & Worrell, E. (2013). The energy required to produce materials: Constraints on energy-intensity improvements, parameters of demand. https://doi.org/10.1098/rsta.2012.0003
 Ingarao, G. (2017). Manufacturing strategies for efficiency in energy and resources use: The role of metal shaping processes. Journal of Cleaner Production, 142, 2872–2886. https://doi.org/10.1016/j.jclepro.2016.10.182
 European Aluminum Association, 2013. Environmental Profile Report for the European Aluminium Industry.
 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).
 Vargel, C., 2004. Corrosion of Aluminium. Elsevier. https://doi.org/10.1016/B978-008044495-6/50012-4
 Simon, L., Moraes, C. A. M., Modolo, R. C. E., Vargas, M., Calheiro, D., & Brehm, F. A. (2017). Recycling of contaminated metallic chip based on eco-efficiency and eco-effectiveness approaches. Journal of Cleaner Production, 153, 417–424. https://doi.org/10.1016/j.jclepro.2016.11.058
 Grayson J., 2017. Reducing Melt Loss and Dross Generation.
 Baffari D, Buffa G, Campanella D, Fratini L, Micari F. 2014. Friction based Solid State Welding Techniques for Transportation Industry Applications. https://doi.org/10.1016/j.procir.2014.06.125
 D. Baffari, A.P. Reynolds, X. Li, L. Fratini, Influence of processing parameters and initial temper on friction stir extrusion of 2050 aluminum alloy, Journal of Manufacturing Processes, 28 (2017) 319–325. https://doi.org/10.1016/j.jmapro.2017.06.013
 D. Baffari, G. Buffa, D. Campanella, L. Fratini, Al-SiC metal matrix composite production through friction stir extrusion of aluminum chips, Procedia Engineering, 207 (2017) 419–424. https://doi.org/10.1016/j.proeng.2017.10.798
 D. Baffari, G. Buffa, D. Campanella, L. Fratini, A.P. Reynolds, Process mechanics in friction stir extrusion of magnesium alloys chips through experiments and numerical simulation, Journal of Manufacturing Processes, 29 (2017) 41–49. https://doi.org/10.1016/j.jmapro.2017.07.010
 D. Baffari, G. Buffa, L. Fratini, A numerical model for wire integrity prediction in friction stir extrusion of magnesium alloys, Journal of Materials Processing Technology, 247 (2017) 1–10. https://doi.org/10.1016/j.jmatprotec.2017.04.007
 Tekkaya AE. Simulation of Metal Forming Processes 2000:251–302. https://doi.org/10.1007/978-3-662-04013-3_7
 Baffari Dario; Buffa Gianluca; Fratini Livan (2017). A numerical model for Wire integrity prediction in Friction Stir Extrusion of magnesium alloys. Journal of Materials Processing Technology, 247, 1. https://doi.org/10.1016/j.jmatprotec.2017.04.007