Critical analysis of friction stir-based manufacturing processes

In this study, a detailed analysis of friction stir-based processes that can significantly contribute to joining of materials and surface property enhancement has been completed. Past, present, and future projections, advantages and disadvantages, technological barriers, and drawbacks of these processes have been given. Detailed explanations of the recent developments of friction stir-based processes and main components are given. Potential industrial applications have been assessed and evaluated using economic and technological considerations. In industrial applications, friction stir-based processes can be used in conjunction with additive processes such as laser-engineered near net shaping, thermal spraying and laser-assisted direct metal deposition processes. Developments in friction stir-based processes have led to improved metallurgical and mechanical properties such as microstructure modification, refinement, homogenization, surface cladding, corrosion, fatigue, wear, and hardness of metallic materials. The results of the study conclusively predict that reasonable costs and improved properties of processed materials will lead to a substantial increase in the use of friction stir-based processes.