Skip to main content
SpringerLink
Log in

Friction Stir Processing Technology: A Review

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

Friction stir processing (FSP), developed based on the basic principles of friction stir welding (FSW), a solid-state joining process originally developed for aluminum alloys, is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components. The FSP causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity of the processed zone. The FSP technique has been successfully used for producing the fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite and intermetallic compound in situ. In this review article, the current state of the understanding and development of FSP is addressed.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25

Similar content being viewed by others

References

  1. W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Templesmith, and C.J. Dawes: G.B. Patent Application No. 9125978.8, Dec. 1991.

  2. R.S. Mishra, Z.Y. Ma: Mater. Sci. Eng., R, 2005, vol. R50, pp. 1–78

    Article  CAS  Google Scholar 

  3. M.W. Mahoney, C.G. Rhodes, J.G. Flintoff, R.A. Spurling, W.H. Bingel: Metall. Mater. Trans. A, 1998, vol. 29A, pp. 1955–64

    Article  CAS  Google Scholar 

  4. J.Q. Su, T.W. Nelson, R. Mishra, M. Mahoney: Acta Mater., 2003, vol. 51, pp. 713–29

    Article  CAS  Google Scholar 

  5. Ø. Frigaard, Ø. Grong, J. Hjelen, S. Gulbrandsen-Dahl, and O.T. Midling: Proc. 1st Int. Symp. on Friction Stir Welding, Thousand Oaks, CA, 1999, TWI, Cambridge, 1999.

  6. G. Bussu, P.E. Irving: Int. J. Fatigue, 2003, vol. 25, pp. 77–88

    Article  CAS  Google Scholar 

  7. W.B. Lee, Y.M. Yeon, S.B. Jung: Mater. Sci. Technol., 2003, vol. 19, pp. 785–90

    Article  CAS  Google Scholar 

  8. J.A. Esparza, W.C. Davis, L.E. Murr: J. Mater. Sci., 2003, vol. 38, pp. 941–52

    Article  CAS  Google Scholar 

  9. R.A. Prado, L.E. Murr, D.J. Shindo, K.F. Sota: Scripta Mater., 2001, vol. 45, pp. 75–80

    Article  CAS  Google Scholar 

  10. L. Ceschini, I. Boromei, G. Minak, A. Morri, F. Tarterini: Compos. Sci. Technol., 2007, vol. 67, pp. 605–15

    Article  CAS  Google Scholar 

  11. K. Kimapong, T. Watanabe: Weld. J., 2004, vol. 83, pp. 277S–282S

    Google Scholar 

  12. C.M. Chen, R. Kovacevic: Int. J. Mach. Tool. Manuf., 2004, vol. 44, pp. 1205–14

    Article  Google Scholar 

  13. G. Campbell, T. Stotler: Weld. J., 1999, vol. 78, pp. 45–47

    CAS  Google Scholar 

  14. K.J. Colligan, J.J. Fisher, J.E. Gover, J.R. Pickens: Adv. Mater. Processes, 2002, vol. 160, pp. 39–41

    CAS  Google Scholar 

  15. J. Ding, R. Carter, K. Lawless, A. Nunes, C. Russel, M. Suits, J. Schneider: Weld. J., 2006, vol. 85, pp. 55–59

    Google Scholar 

  16. W.J. Arbegast: Weld. J., 2006, vol. 85, pp. 28–35

    CAS  Google Scholar 

  17. R.S. Mishra, M.W. Mahoney, S.X. McFadden, N.A. Mara, A.K. Mukherjee: Scripta Mater., 2000, vol. 42, pp. 163–68

    CAS  Google Scholar 

  18. R.S. Mishra, M.W. Mahoney: Mater. Sci. Forum, 2001, vols. 357–359, pp. 507–12

    Google Scholar 

  19. Z.Y. Ma, R.S. Mishra, M.W. Mahoney: Acta Mater., 2002, vol. 50, pp. 4419–30

    Article  CAS  Google Scholar 

  20. R.S. Mishra, Z.Y. Ma, I. Charit: Mater. Sci. Eng., A, 2002, vol. A341, pp. 307–10

    Google Scholar 

  21. P.B. Berbon, W.H. Bingel, R.S. Mishra, C.C. Bampton, M.W. Mahoney: Scripta Mater., 2001, vol. 44, pp. 61–66

    Article  CAS  Google Scholar 

  22. J.E. Spowart, Z.Y. Ma, and R.S. Mishra: in Friction Stir Welding and Processing II, K.V Jata, M.W Mahoney, R.S Mishra, S.L Semiatin, and T. Lienert, eds., TMS, Warrendale, PA, 2003, pp. 243–52

  23. Z.Y. Ma, S.R. Sharma, R.S. Mishra, M.W. Mahoney: Mater. Sci. Forum, 2003, vols. 426–432, pp. 2891–96

    Article  Google Scholar 

  24. C.J. Lee, J.C. Huang, P.J. Hsieh: Scripta Mater., 2006, vol. 54, pp. 1415–20

    Article  CAS  Google Scholar 

  25. Y. Morisada, H. Fujii, T. Nagaoka, M. Fukusumi: Mater. Sci. Eng., A, 2006, vol. A419, pp. 344–48

    CAS  Google Scholar 

  26. Y. Morisada, H. Fujii, T. Nagaoka, M. Fukusumi: Mater. Sci. Eng., A, 2006, vol. A433, pp. 50–54

    CAS  Google Scholar 

  27. M. Dixit, J.W. Newkirk, R.S. Mishra: Scripta Mater., 2007, vol. 56, pp. 541–44

    Article  CAS  Google Scholar 

  28. S.R. Sharma, Z.Y. Ma, R.S. Mishra, M.W. Mahoney: Scripta Mater., 2004, vol. 51, pp. 237–41

    Article  CAS  Google Scholar 

  29. Z.Y. Ma, S.R. Sharma, R.S. Mishra, M.W. Mahoney: Metall. Mater. Trans. A, 2006, vol. 37A, pp. 3323–36

    Article  CAS  Google Scholar 

  30. Z.Y. Ma, S.R. Sharma, R.S. Mishra: Scripta Mater., 2006, vol. 54, pp. 1623–26

    Article  CAS  Google Scholar 

  31. K. Oh-ishi, T.R. McNelley: Metall. Mater. Trans. A, 2004, vol. 35A, pp. 2951–61

    Article  CAS  Google Scholar 

  32. A.H. Feng, Z.Y. Ma: Scripta Mater., 2007, vol. 56, pp. 397–400

    Article  CAS  Google Scholar 

  33. C.J. Hsu, P.W. Kao, N.J. Ho: Scripta Mater., 2005, vol. 53, pp. 341–45

    CAS  Google Scholar 

  34. C.H. Chuang, J.C. Huang, P.J. Hsieh: Scripta Mater., 2005, vol. 53, pp. 1455–60

    Article  CAS  Google Scholar 

  35. C.J. Hsu, C.Y. Chang, P.W. Kao, N.J. Ho, C.P. Chang: Acta Mater., 2006, vol. 54, pp. 5241–49

    Article  CAS  Google Scholar 

  36. Z.Y. Ma, R.S. Mishra: Scripta Mater., 2005, vol. 53, pp. 75–80

    Article  CAS  Google Scholar 

  37. C.G. Rhodes, M.W. Mahoney, W.H. Bingel, M. Calabrese: Scripta Mater., 2003, vol. 48, pp. 1451–55

    Article  CAS  Google Scholar 

  38. J.Q. Shu, T.W. Nelson, C.J. Sterling: J. Mater. Res., 2003, vol. 18, pp. 1757–60

    Google Scholar 

  39. J.Q. Shu, T.W. Nelson, C.J. Sterling: Scripta Mater., 2005, vol. 52, pp. 135–40

    Article  CAS  Google Scholar 

  40. A.F. Norman, I. Brough, P.B. Prangnell: Mater. Sci. Forum, 2000, vols. 331–337, pp. 1713–18

    Google Scholar 

  41. I. Charit, R.S. Mishra: Mater. Sci. Eng., A, 2003, vol. A359, pp. 290–96

    CAS  Google Scholar 

  42. T.R. McNelley, M.E. McMahon: Metall. Mater. Trans. A, 1997, vol. 28A, pp. 1879–87

    Article  CAS  Google Scholar 

  43. M. Eddahbi, T.R. McNelley, O.A. Ruano: Metall. Mater. Trans. A, 2001, vol. 32A, pp. 1093–1102

    Article  CAS  Google Scholar 

  44. C.I. Chang, C.J. Lee, J.C. Huang: Scripta Mater., 2004, vol. 51, pp. 509–14

    Article  CAS  Google Scholar 

  45. G.R. Cui, Z.Y. Ma and S.X. Li: Institute of Metal Research, Chinese Academy of Sciences, Shenyang, China, unpublished research, 2007.

  46. I. Charit, R.S. Mishra: J. Mater. Res., 2004, vol. 19, pp. 3329–42

    Article  CAS  Google Scholar 

  47. Z.Y. Ma, R.S. Mishra, M.W. Mahoney, R. Grimes: Mater. Sci. Eng., A, 2003, vol. A351, pp. 148–53

    CAS  Google Scholar 

  48. Z.Y. Ma, R.S. Mishra, M.W. Mahoney, R. Grimes: Metall. Mater. Trans. A, 2005, 36A, pp. 1447–58

    Article  CAS  Google Scholar 

  49. I. Charit, R.S. Mishra: Acta Mater., 2005, vol. 53, pp. 4211–23

    Article  CAS  Google Scholar 

  50. Z.Y. Ma, R.S. Mishra: Scripta Mater., 2004, vol. 50, pp. 931–35

    Article  CAS  Google Scholar 

  51. P. Cavaliere, P.P. De Marco: J. Mater. Process. Technol., 2007, vol. 184, pp. 77–83

    Article  CAS  Google Scholar 

  52. P. Cavaliere, P.P. De Marco: J. Mater. Sci., 2006, vol. 41, pp. 3459–64

    Article  CAS  Google Scholar 

  53. M. Mahoney, R.S. Mishra, T. Nelson, J. Flintoff, R. Islamgaliev, and Y. Hovansky: in Friction Stir Welding and Processing, TMS, Warrendale, PA, 2001, p. 183–94.

  54. M. Mahoney, C. Fuller, and W. Bingel: Rockwell Scientific, Thousand Oaks, CA, unpublished research, 2006.

  55. T.R. McNelley, R. Crooks, P.N. Kalu, S.A. Rogers: Mater. Sci. Eng., A, 1993, vol. A106, pp. 135–43

    Google Scholar 

  56. I.C. Hsiao, J.C. Huang: Metall. Mater. Trans. A, 2002, vol. 33A, pp. 1373–84

    Article  CAS  Google Scholar 

  57. R.Z. Valiev, T.G. Langdon: Prog. Mater. Sci., 2006, vol. 51, pp. 881–981

    Article  CAS  Google Scholar 

  58. R.Z. Valiev: Mater. Sci. Forum, 1997, vols. 243–245, pp. 207–16

    Google Scholar 

  59. R.S. Mishra, R.Z. Valiev, S.X. McFadden, R.K. Islamgaliev, A.K. Mukherjee: Philos. Mag. A, 2001, vol. 81, pp. 37–48

    Article  CAS  Google Scholar 

  60. M. Noda, M. Hirohashi, K. Funami: Mater. Trans., 2003, vol. 44, pp. 2288–97

    Article  CAS  Google Scholar 

  61. N. Tsuji, K. Shiotsuki, Y. Saito: Mater. Trans. JIM, 1999, vol. 40, pp. 765–71

    CAS  Google Scholar 

  62. M.W. Mahoney, R. Mishra, and T. Nelson: Proc. 3rd Int. Symp. on Friction Stir Welding, TWI, Kobe, Japan, 2002.

    Google Scholar 

  63. M. Mahoney, A.J. Barrnes, W.H. Bingel, C. Fuller: Mater. Sci. Forum, 2004, vols. 447–448, pp. 505–12

    Google Scholar 

  64. R.S. Mishra: Adv. Mater. Processes, 2004, vol. 162, pp. 45–47

    CAS  Google Scholar 

  65. P. Heurtier, C. Desrayaud, F. Montheillet: Mater. Sci. Forum, 2002, vols. 396–402, pp. 1537–42

    Article  Google Scholar 

  66. Z.Y. Ma and R.S. Mishra: in Surface Engineering: in Materials Science II, S. Seel, N.B. Dahotre, J.J. Moore, C. Suryanarayana, and A. Agarwal, eds., TMS, Warrendale, PA, 2003, pp. 243–50.

  67. C.J. Lee, J.C. Huang: Mater. Trans., 2006, vol. 47, pp. 2773–78

    Article  CAS  Google Scholar 

  68. C.I. Chang, Y.N. Wang, H.R. Pei, C.J. Lee, J.C. Huang: Mater. Trans., 2006, vol. 47, pp. 2942–49

    Article  CAS  Google Scholar 

  69. J.H. Lee, K. Hamada, K. Mizuuchi, M. Taya, K. Inoue: Mater. Res. Soc. Symp., 1997, vol. 459, pp. 419–24

    CAS  Google Scholar 

  70. Z.C. Wei, C.Y. Tang, W.B. Lee: J. Mater. Process. Technol., 1997, vol. 69, pp. 68–74

    Article  Google Scholar 

  71. D.L. Zalensas: Aluminum Casting Technology, 2nd ed., AFS Inc., Schaumburg, IL, 1993, p. 77

    Google Scholar 

  72. D.L. Zhang, L. Zheng: Metall. Mater. Trans. A, 1996, vol. 27A, pp. 3983–91

    Article  CAS  Google Scholar 

  73. G. Atxaga, A. Pelayo, A.M. Irisarri: Mater. Sci. Technol., 2001, vol. 17, pp. 446–50

    Article  CAS  Google Scholar 

  74. K.T. Kashyap, S. Murrall, K.S. Raman, K.S.S. Murthy: Mater. Sci. Technol., 1993, vol. 9, pp. 189–203

    CAS  Google Scholar 

  75. L. Wang, S. Shivkumar: Z. Metallkd., 1995, vol. 86, pp. 441–45

    CAS  Google Scholar 

  76. M.L. Santella, T. Engstrom, D. Storjohann, T.Y. Pan: Scripta Mater., 2005, vol. 53, pp. 201–06

    Article  CAS  Google Scholar 

  77. K. Nakata, Y.G. Kim, H. Fujii, T. Tsumura, T. Komazaki: Mater. Sci. Eng., A, 2006, vol. 437, pp. 274–80.

    Article  CAS  Google Scholar 

  78. Z.Y. Ma, A.L. Pilchak, M.C. Juhas, and J.C. Williams: Scripta Mater., 2008, vol. 58, pp. 361–66

    Article  CAS  Google Scholar 

  79. M. Tsujikawa, S.W. Chung, M. Tanaka, Y. Takigawa, S. Oki, K. Higashi: Mater. Trans., 2005, vol. 46, pp. 3081–84

    Article  CAS  Google Scholar 

  80. M. Tsujikawa, S.W. Chung, T. Morishige, L.F. Chiang, Y. Takigawa, S. Oki, K. Higashi: Mater. Trans., 2007, vol. 48, pp. 618–21

    Article  CAS  Google Scholar 

  81. D. Zhang, M. Suzuki, K. Maruyama: Scripta Mater., 2005, vol. 52, pp. 899–903

    Article  CAS  Google Scholar 

  82. D. Zhang, M. Suzuki, K. Maruyama: Mater. Sci. Forum, 2007, vols. 539–543, pp. 3739–44

    Google Scholar 

  83. K. Mathis, J. Gubicza, N.H. Nam: J. Alloys Compd., 2005, vol. 394, pp. 194–99

    Article  CAS  Google Scholar 

  84. S. Kleiner, O. Beffort, P.J. Uggowitzer: Scripta Mater., 2004, vol. 51, pp. 405–10

    Article  CAS  Google Scholar 

  85. B. Askari, S. Silling, B. London, M. Mahoney: JOM, 2004, vol. 56, pp. 245–46

    Google Scholar 

  86. T. Long, T.U. Seidel, W. Tang, A.P. Reynolds: Hot Deformation of Aluminum Alloys III—TMS Annual Meeting, TMS, Warrendale, PA, 2003, pp. 299–312.

    Google Scholar 

  87. R.L. Goetz and K.V. Jata: in Friction Stir Welding and Processing, TMS, Warrendale, PA, 2001, pp. 35–42.

  88. S. Celotto, T.J. Bastow: Acta Mater., 2001, vol. 49, pp. 41–51

    Article  CAS  Google Scholar 

  89. J.A. Duma: Nav. Eng. J., 1975, vol. 87, pp. 45–64

    CAS  Google Scholar 

  90. R.J. Ferrara, T.E. Caton: Mater. Performance, 1982, vol. 21, pp. 30–34

    CAS  Google Scholar 

  91. M. Mahoney, W. Bingel, S. Sharma, R. Mishra: Mater. Sci. Forum, 2003, vols. 426–432, pp. 2843–48

    Google Scholar 

  92. K. Oh-ishi, T. McNelley: Metall. Mater. Trans. A, 2004, vol. 35A, pp. 2951–61

    Article  CAS  Google Scholar 

  93. K. Oh-ishi, T. McNelley: Metall. Mater. Trans. A, 2005, vol. 36A, pp. 1575–85

    Article  CAS  Google Scholar 

  94. K. Oh-ishi, A.P. Zhilyaev, T. McNelley: Mater. Sci. Forum, 2006, vols. 503–504, pp. 161–68

    Google Scholar 

  95. T. McNelley, K. Oh-ishi, A.P. Zhilyaev: Mater. Sci. Forum, 2007, vols. 539–543, pp. 3745–50

    Google Scholar 

  96. M. Mahoney, C. Fuller, W.H. Bingel, M. Calabrese: Mater. Sci. Forum, 2007, vols. 539–543, pp. 3721–26

    Article  Google Scholar 

  97. C.B. Fuller, M.W. Mahoney, W.H. Bingel, M. Calabrese, B. London: Mater. Sci. Forum, 2007, vols. 539–543, pp. 3751–76

    Google Scholar 

  98. D. Eylon and B. Strope: J. Mater. Sci., 1979, vol. 14, pp. 345–53.

    Article  CAS  Google Scholar 

  99. A.L. Pilchak, M.C. Juhas, J.C. Williams: Metall. Mater. Trans. A, 2007, vol. 38A, pp. 401–08

    Article  CAS  Google Scholar 

  100. A.L. Pilchak, D.M. Norfleet, M.C. Juhas, J.C. Williams: Metall. Mater. Trans. A, in press

  101. A.L. Pilchak, M.C. Juhas, and J.C. Williams: Proc. 11th World Conf. on Titanium, Kyoto, Japan, 2007, in press.

  102. G. Lütjering, J.C. Williams: Titanium, Springer-Verlag, Berlin, 2003, p. 63

    Google Scholar 

  103. V.V.B. Prasad, B.V.R. Bhat, Y.R. Mahajan, P. Ramakrishnan: Mater. Manuf. Processes, 2001, vol. 16, pp. 841–53

    Article  CAS  Google Scholar 

  104. S.C. Tjong, Z.Y. Ma: Compos. Sci. Technol., 1999, vol. 59, pp. 1117–25

    Article  CAS  Google Scholar 

  105. A. Slipenyuk, V. Kuprin, Y. Milman, J.E. Spowart, D.B. Miracle: Mater. Sci. Eng., A, 2004, vol. 381, pp. 165–70

    Article  CAS  Google Scholar 

  106. B.L. Xiao, J.Z. Fan, X.F. Tian, W.Y. Zhang, L.K. Shi: J. Mater. Sci., 2005, vol. 40, pp. 5757–62

    Article  CAS  Google Scholar 

  107. V.V.B. Prasad, B.V.R. Bhat, Y.R. Mahajan, P. Ramakrishnan: Mater. Sci. Eng., A, 2002, vol. 337, pp. 179–86

    Article  Google Scholar 

  108. G. Biallas, R. Braun, C.D. Donne, G. Staniek, W.A. Keysser: Proc. 1st Int. Symp. on Friction Stir Welds, Thousand Oaks, CA, 1999.

    Google Scholar 

  109. M.A. Meyers, A. Mishra, D.J. Benson: Prog. Mater. Sci., 2006, vol. 51, pp. 427–556

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The author gratefully acknowledges the support of the National Outstanding Young Scientist Foundation under Grant No. 50525103, the National Basic Research Program of China under Grant No. 2006CB605205, the National High-Tech Research Program of China under Grant No. 2006AA03Z111, and the Hundred Talents Program of the Chinese Academy of Sciences.

Author information

Authors and Affiliations

  1. Institute of Metal Research, Chinese Academy of Sciences, Shenyang, P.R. China

    Z.Y. Ma (Professor)

Authors
  1. Z.Y. Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Z.Y. Ma.

Additional information

Manuscript submitted August 16, 2007.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Ma, Z. Friction Stir Processing Technology: A Review. Metall Mater Trans A 39, 642–658 (2008). https://doi.org/10.1007/s11661-007-9459-0

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-007-9459-0

Keywords

Search

Navigation