Comparative analysis of Friction Stir Processing (FSP) for different sheet metal parts using tool and die

Abstract

Friction Stir Processing (FSP) is a solid state, joining process which is derived from the Friction Stir welding (FSW). It was developed by The Welding Institute (TWI) of United Kingdom in 1991. In this process during a single pass, the mechanical and microstructural properties of the material are improved significantly. Friction stir processing was performed in this research work on AA 6061-T6 and Cartridge Brass with thickness of 3mm prior to bending to improve the bending limit. For Friction stir processing H13 tool steel with square pin profile was used with different rotational speed and feed rate for both materials. Different process parameters such as punch displacement, material type, sheet thickness was considered for sheet metal bending. Microstructure analysis was carried out to analyze the microstructure. Tensile testing was done to determine the UTS. Hardness for all the distinct zones were determined through micro hardness testing. It was concluded that Friction stir processing refines the grain structure and springback was reduced after FSP in both AA 6061-T6 and Cartridge Brass, resulting in much greater bending limits as compared to samples without FSP in the range of 1-2°.