Research progress in friction stir processing of magnesium alloys and their metal matrix surface composites: Evolution in the 21^(st )century

Rising concerns about climate change drive the demand for lightweight components.Magnesium(Mg)alloys are highly valued for their low weight,making them increasingly important in various industries.Researchers focusing on enhancing the characteristics of Mg alloys and developing their Metal Matrix Composites(MMCs)have gained significant attention worldwide over the past decade,driven by the global shift towards lightweight materials.Friction Stir Processing(FSP)has emerged as a promising technique to enhance the properties of Mg alloys and produce Mg-MMCs.Initially,FSP adapted to refine grain size from the micro to the nano level and accelerated the development of MMCs due to its solid-state nature and the synergistic effects of microstructure refinement and reinforcement,improving strength,hardness,ductility,wear resistance,corrosion resistance,and fatigue strength.However,producing defect-free and sound FSPed Mg and Mg-MMCs requires addressing several variables and their interdependencies,which opens up a broad range of practical applications.Despite existing reviews on individual FSP of Mg,its alloys,and MMCs,an attempt has been made to analyze the latest research on these three aspects collectively to enhance the understanding,application,and effectiveness of FSP for Mg and its derivatives.This review article discusses the literature,classifies the importance of Mg alloys,provides a historical background,and explores developments and potential applications of FSPed Mg alloys.It focuses on novel fabrication methods,reinforcement strategies,machine and tool design parameters,material characterization,and integration with other methods for enhanced properties.The influence of process parameters and the emergence of defects are examined,along with specific applications in mono and hybrid composites and their microstructure evolution.The study identifies promising reinforcement materials and highlights research gaps in FSP for Mg alloys and MMCs production.It concludes with significant recommendations for further exploration,reflecting ongoing advancements in this field.

Identification of processing window for extrusion of large thick-walled Inconel 625 alloy pipes using response surface methodology

Identifying suitable processing window is necessary but difficult for achieving favorable microstructure and performance in extrusion of large thick-walled pipe with difficult-to-deform Inconel 625 alloy. In this work, a method was established for identifying the extrusion process window considering temperature control using response surface methodology. Firstly, the response surface models, which correlate temperature rise and peak temperature to key extrusion parameters, have been developed by orthogonal regression based on finite element calculated data. Secondly, the coupled effects of the key extrusion parameters on the temperature rise and peak temperature have been disclosed based on the regression models. Lastly, suitable extrusion processing windows, which are described by contour map of peak temperature in the space of extrusion speed and initial billet temperature, have been established for different extrusion ratios. Using the identified process window, a suitable combination of the key extrusion parameters can be determined conveniently and quickly.

Microstructure and texture evolution in titanium subjected to friction roll surface processing and subsequent annealing

Commercial purity and high purity titanium sheets were initially strained by a new technique, named as friction roll surface processing （FRSP）. Severe strain was imposed into the surface layer and strain gradient was formed through the thickness of the sheet. The microstructure and texture in as-strained state were investigated by optical microscopy and X-ray diffraction technique On the surface of the sheets, ultra-fine grains were found to have a sharp texture with a preferred orientation strongly related to the FRSP direction. The evolution of microstructure and crystallographic texture of FRSPed samples during recrystallization were also studied by electron back-scattered diffraction （EBSD） technique after being annealed at selected temperatures and time. The results indicated that the preferred orientations resulting from FRSP and annealing in the surface layer were formed during rolling and its recrystallization textures were reduced by FRSP. In addition, the texture evolved stably without change in main components during the annealing.

Mechanical Properties and Microstructure of Bionic Non-Smooth Stainless Steel Surface by Laser Multiple Processing

Laser multiple processing, i.e. laser surface texturing and then Laser Shock Processing (LSP), is a new surface processing technology for the preparation of bionic non-smooth surfaces. Based on engineering bionics, samples of bionic non-smooth surfaces of stainless steel 0Crl 8Ni9 were manufactured in the form of reseau structure by laser multiple processing. The mechanical properties (including microhardness, residual stress, surface roughness) and microstructure of the samples treated by laser multiple processing were compared with those of the samples without LSP The results show that the mechanical properties of these samples by laser multiple processing were clearly improved in comparison with those of the samples without LSP The mechanisms underlying the improved surface microhardness and surface residual stress were analyzed, and the relations between hardness, comnressive residual stress and roughness were also presented.

Magnesium based surface metal matrix composites by friction stir processing

Surface metal matrix composites(MMCs)are a group of modern engineered materials where the surface of the material is modified by dispersing secondary phase in the form of particles or fibers and the core of the material experience no change in chemical composition and structure.The potential applications of the surface MMCs can be found in automotive,aerospace,biomedical and power industries.Recently,friction stir processing(FSP)technique has been gaining wide popularity in producing surface composites in solid state itself.Magnesium and its alloys being difficult to process metals also have been successfully processed by FSP to fabricate surface MMCs.The aim of the present paper is to provide a comprehensive summary of state-of-the-art in fabricating magnesium based composites by FSP.Influence of the secondary phase particles and grain refinement resulted from FSP on the properties of these composites is also discussed.

Surface Inspection System for Cold Rolled Strips Based on Image ProcessingTechnique

A new surface inspection system for cold rolled strips based on image processing is introduced. The system is equipped withtwo different illumination structures and CCD matrix cameras. The structure and image processing of the inspection system are described. Some efficient algorithms for image processing and classification are presented. The system is tested with strip samples fromcold rolling plants. The results show that the system can detect and recognize six common defects of cold rolled strips successfully.

Influence of tool rotational speed on microstructure and sliding wear behavior of Cu/B_4C surface composite synthesized by friction stir processing

An attempt was made to synthesize Cu/B4C surface composite using friction stir processing（FSP） and to analyze the influence of tool rotational speed on microstructure and sliding wear behavior of the composite. The tool rotational speed was varied from 800 to 1200 r/min in step of 200 r/min. The traverse speed, axial force, groove width and tool pin profile were kept constant. Optical microscopy and scanning electron microscopy were used to study the microstructure of the fabricated surface composites. The sliding wear behavior was evaluated using a pin-on-disc apparatus. The results indicate that the tool rotational speed significantly influences the area of the surface composite and the distribution of B4C particles. Higher rotational speed exhibits homogenous distribution of B4C particles, while lower rotational speed causes poor distribution of B4C particles in the surface composite. The effects of tool rotational speed on the grain size, microhardness, wear rate, worn surface and wear debris were reported.

AIRIS:Artificial Intelligence Enhanced Signal Processing in Reconfigurable Intelligent Surface Communications

Reconfigurable intelligent surface(RIS)is an emerging meta-surface that can provide additional communications links through reflecting the signals,and has been recognized as a strong candidate of 6G mobile communications systems.Meanwhile,it has been recently admitted that implementing artificial intelligence(AI)into RIS communications will extensively benefit the reconfiguration capacity and enhance the robustness to complicated transmission environments.Besides the conventional model-driven approaches,AI can also deal with the existing signal processing problems in a data-driven manner via digging the inherent characteristic from the real data.Hence,AI is particularly suitable for the signal processing problems over RIS networks under unideal scenarios like modeling mismatching,insufficient resource,hardware impairment,as well as dynamical transmissions.As one of the earliest survey papers,we will introduce the merging of AI and RIS,called AIRIS,over various signal processing topics,including environmental sensing,channel acquisition,beamforming design,and resource scheduling,etc.We will also discuss the challenges of AIRIS and present some interesting future directions.

VIRTUAL PROCESSING OF LASER SURFACE HARDENING ON AUTOBODY DIES

A new method of collision-free path plan integrated in virtual processing is developed to improve the efficiency of laser surface hardening on dies. The path plan is based on the premise of no collision and the optimization object is the shortest path. The optimization model of collision-free path is built from traveling salesman problem （TSP）. Collision-free path between two machining points is calculated in configuration space （C-Space）. Ant colony optimization （ACO） algorithm is applied to TSP of all the machining points to find the shortest path, which is simulated in virtual environment set up by IGRIP software. Virtual machining time, no-collision report, etc, are put out atter the simulation. An example on autobody die is processed in the virtual platform, the simulation results display that ACO has perfect optimization effect, and the method of virtual processing with integration of collision-free optimal path is practical.

A comparative study between friction stir processing and friction stir vibration processing to develop magnesium surface nanocomposites

Friction stir processing(FSP)can be used to improve surface composites.In this study,a modified method of FSP called friction stir vibration processing(FSVP)was applied to develop a surface composite on AZ91 magnesium alloy.In this technique,the workpiece is vibrated normal to the processing direction.The results illustrated that compared with the FSP method,the FSVP caused a better homogeneous distribution of SiC particles in the microstructure.The results also showed that matrix grains of friction stir vibration processed(FSV-processed)samples((26.43±2.00)μm)were finer than those of friction stir processed(FS-processed)specimens((39.43±2.00)μm).The results indicated that the ultimate tensile strength(UTS)of FSV-processed specimens(361.82 MPa)was higher than that of FS-processed specimens(324.97 MPa).The higher plastic strain in the material during FSVP,due to workpiece vibration,resulted in higher dynamic recrystallization,and consequently,finer grains were developed.The elongation and formability index of the FSV-processed specimen(16.88%and 6107.52 MPa·%,respectively)were higher than those of the FS-processed sample(15.24%and 4952.54 MPa·%,respectively).Moreover,the effects of FSVP were also found to intensify as the vibration frequency increased.

Surface metal-matrix composites based on AZ91 magnesium alloy via friction stir processing:A review

This monograph presents an overview of friction stir processing(FSP)of surface metal-matrix composites(MMCs)using the AZ91 magnesium alloy.The reported results in relation to various reinforcing particles,including silicon carbide(SiC),alumina(Al_(2)O_(3)),quartz(SiO_(2)),boron carbide(B_(4)C),titanium carbide(TiC),carbon fiber,hydroxyapatite(HA),in-situ formed phases,and hybrid reinforcements are summarized.AZ91 composite fabricating methods based on FSP are explained,including groove filling(grooving),drilled hole filling,sandwich method,stir casting followed by FSP,and formation of in-situ particles.The effects of introducing second-phase particles and FSP process parameters(e.g.,tool rotation rate,traverse speed,and the number of passes)on the microstructural modification,grain refinement,homogeneity in the distribution of particles,inhibition of grain growth,mechanical properties,strength–ductility trade-off,wear/tribological behavior,and corrosion resistance are discussed.Finally,useful suggestions for future work are proposed,including focusing on the superplasticity and superplastic forming,metal additive manufacturing processes based on friction stir engineering(such as additive friction stir deposition),direct FSP,stationary shoulder FSP,correlation of the dynamic recrystallization(DRX)grain size with the Zener–Hollomon parameter similar to hot deformation studies,process parameters(such as the particle volume fraction and external cooling),and common reinforcing phases such as zirconia(ZrO_(2))and carbon nanotubes(CNTs).

3D surface profile diagnosis using digital image processing for laboratory use

The measurement of the surface quality and the profile preciseness is major issues in many industrial branches such that the surface quality of semi products directly affects the subsequent production steps.Although,there are many ways to obtain required data,the hardware necessary for the measurements such as 2D or 3D scanners,depending on the problem’s complexity,is too expensive.Therefore,in this paper,what we put forward as a novelty is an algorithm which is verified on the model of simple 3D scanner on the image processing basis with the resolution of 0.1 mm.There are many ways to scan surface profile;however,the image processing currently is the most trending topic in industry automation.Most importantly,in order to obtain surface images,standard high resolution reflex camera is used and thus the post processing could be realized with MatLab as the software environment.Therefore,this solution is an alternative to the expensive scanners,and single-purpose devices could be extended by many additional functions.

Friction Stir Processing of Thixoformed AZ91D Magnesium Alloy and Fabrication of Surface Composite Reinforced by SiC_ps

The microstructural evolution characteristics of the thermomechanically affected zone （TMAZ） alloy during friction stir processing （FSP） of thixoformed （TF） AZ91D alloy were investigated. Simultaneously, a surface composite layer reinforced by SiC particles （SiCps） was prepared on the alloy by FSP and the corresponding tribological properties were examined. The experimental results indicate that dynamic recrystallization and mechanical separation （including splitting and fracture of the primary grains） are the main mechanisms of grain refinement for the TMAZ. A composite surface reinforced by uniformly distributed SiCps was prepared on the alloy. Compared with the corresponding permanent mould casting alloy and the TF alloy without composite surface, the TF alloy with composite surface has the highest wear resistance and lowest friction coefficient.

Ship hull plate processing surface fairing with constraints based on B-spline

The problem of ship hull plate processing surface fairing with constraints based on B-spline is solved in this paper. The algorithm for B-spline curve fairing with constraints is one of the most common methods in plane curve fairing. The algorithm can be applied to global and local curve fairing. It can constrain the perturbation range of the control points and the shape variation of the curve, and get a better fairing result in plane curves. In this paper, a new fairing algorithm with constraints for curves and surfaces in space is presented. Then this method is applied to the experiments of ship hull plate processing surface. Finally numerical results are obtained to show the efficiency of this method.

Parallel Image Processing Technology of Surface Detection System

To improve image processing speed and detection precision of a surface detection system on a strip surface,based on the analysis of the characteristics of image data and image processing in detection system on the strip surface,the design of parallel image processing system and the methods of algorithm implementation have been studied. By using field programmable gate array(FPGA) as hardware platform of implementation and considering the characteristic of detection system on the strip surface,a parallel image processing system implemented by using multi IP kernel is designed. According to different computing tasks and the load balancing capability of parallel processing system,the system could set different calculating numbers of nodes to meet the system's demand and save the hardware cost.

Investigation of the processing technology and mechanism of Kansui radix by licorice based on response surface methodology and integrative pharmacology

Background:The herbs should be processed by different methods before use,and the efficacy and toxicity of Chinese herbal medicines may change,which may enhance efficacy and reduce toxicity after processing.Gansui(Kansui radix)is a common clinical herbal medicine,and there are considerable changes in its toxicity and efficacy after processing.Gaocao(Glycyrrhizae radix et rhizome)has a detoxifying effect.Methods:Using the contents of euphorbiadienol and the alcohol-soluble extract of Glycyrrhizae radix-processed Kansui radix as evaluation indexes,response surface methodology was used to optimize the processing technology of Kansui radix by exploring the effects of Glycyrrhizae radix et rhizoma-addition amount,frying temperature,and frying time on the processing technology of Kansui radix.Meanwhile,response surface software was used to analyze experimental data to determine the processing parameters of Kansui radix by Glycyrrhizae radix et rhizoma.Integrative Pharmacology-based Research Platform of Traditional Chinese Medicine is used to analysis the potential ingredients of Kansui radix and verify the potential ingredients by western blotting.Results:The technology of Glycyrrhizae radix et rhizoma-processed Kansui radix was optimized for the Glycyrrhizae radix et rhizoma-addition amount of 27%,frying temperature of 180℃,and frying time of 11 min.The network pharmacology analysis revealed that Kansui radix could cause kidney,liver,and heart injury by the PI3K/AKT signaling pathway.Kansui radix at high or low dose could decrease the ratio of p-AKT/AKT while Glycyrrhizae radix et rhizoma-processed Kansui could increase it.Conclusion:The model established by response surface methodology is relatively accurate and can predict the contents of euphorbiadienol and alcohol extract of processed Kansui radix.The toxic effects and its mechanism of action of Kansui radix and processed Kansui radix on kidney,liver,and heart,from the perspective of systems biology,have provided scientific evidence to its clinical application.

Nanocrystallization of Cementite in 0.4C-1Cr Steel During High-Power Surface Processing

The microstructures of the nanocrystalline surface layer of a quenched and high temperature tempered 0. 4C- 1Cr steel induced by high-power surface processing （HPSP） technique were characterized by scan- ning eleetron microscopy and transmission electron microscopy. The results indicate that a nanocrystalline layer was fabricated on the surface of the steel 19 using HPSP treatment. The mean grain size in the surface layer is about 11 nm. The nanocrystallization of cementite is prior to that of the matrix phase, ferrite.

Influence of Al_2O_3 particles on the microstructure and mechanical properties of copper surface composites fabricated by friction stir processing

The influence of three factors, such as volume percentage of reinforcement particles(i.e. Al2O3), tool tilt angle and concave angle of shoulder, on the mechanical properties of Cue Al2O3 surface composites fabricated via friction stir processing was studied. Taguchi method was used to optimize these factors for maximizing the mechanical properties of surface composites. The fabricated surface composites were examined by optical microscope for dispersion of reinforcement particles. It was found that Al2O3 particles are uniformly dispersed in the stir zone. The tensile properties of the surface composites increased with the increase in the volume percentage of the Al2O3 reinforcement particles.This is due to the addition of the reinforcement particles which increases the temperature of recrystallization by pinning the grain boundaries of the copper matrix and blocking the movement of the dislocations. The observed mechanical properties are correlated with microstructure and fracture features.

Influence of processing parameters on coating surface roughness of aluminum alloy

The influence of processing parameters on the coating surface roughness of LD10 aluminum alloy treated by the power source with positive and negative pulse in the alkaline electrolyte was discussed.Lots of experiments were done with different processing parameters including the positive final voltage,the negative final voltage,the frequency,the duty ratio,the processing time and electrolyte temperature.And the surface roughness tester TR200 was used to measure the coating surface roughness.The influence of the processing time on the surface roughness is the smallest,less than 0.2μm.The surface roughness decreases gradually with the duty ratio decreasing or the frequency increasing;it decreases gradually with each of the other parameters increasing,and then increases gradually after achieving the minimum value.Appropriately by selecting processing parameters,the coating with Ra 0.6 can be obtained.

Experimental investigation of laser surface processing of flexure silicon nitride ceramic

A continuous wave carbon dioxide (CO2) laser (λ=10.6μm) was employed to treat the surface of Si3N4 MOR (modulus of rupture) bars. The effects of the CO2 laser process on physical and mechanical properties of ground Si3N4 samples were investigated. Scanning electron microscopy (SEM) analysis shows that the area occupied by cavities and fracture is decreased by about 49.4% after laser treatments. Cross-sectional metallography results indicate that the secondary YSiAlON phase in the Si3N4 ceramic is softened/melted and flowed into the defects. Four-point bending tests show that the flexural strength of the treated samples is improved to 10.9%. Fractographic analysis show that the fracture origins move from the surface to subsurface. It is concluded that laser surface processing have significant effects on fracture behavior of flexure Si3N4 ceramic.