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<p>About the Editors xv</p> <p>List of Contributors xviii</p> <p>Preface xxv</p> <p>Acknowledgements xxix</p> <p>List of Figures xxx</p> <p>List of Tables xl</p> <p><b>1 Friction Stir Welding: An Overview 1<br /> </b><i>Farooz A. Najar, Shazman Nabi, Sandeep Rathee, and Manu Srivastava</i></p> <p>1.1 Introduction 1</p> <p>1.2 FSW Working Principle 2</p> <p>1.3 Weld Zones 3</p> <p>1.4 Variants of FSW 4</p> <p>1.5 Defects 10</p> <p>1.6 Advantages and Limitations of FSW 11</p> <p>1.7 Conclusion and Future Prospectus 12</p> <p>Acknowledgments 12</p> <p>References 12</p> <p><b>2 Friction Stir Welding and Single-Point Incremental Forming: State-of-the-Art 15<br /> </b><i>Hitesh Mhatre, Amrut Mulay, and Vijay Gadakh</i></p> <p>2.1 Introduction 15</p> <p>2.2 Friction Stir Welding (FSW) 16</p> <p>2.3 Single-Point Incremental Forming (SPIF) 18</p> <p>2.4 FSW and SPIF 21</p> <p>2.5 Summary and Outlook 22</p> <p>References 23</p> <p><b>3 Friction Stir Brazing and Friction Stir Vibration Brazing 25<br /> </b><i>Behrouz Bagheri and Mahmoud Abbasi</i></p> <p>3.1 Introduction to FSB 25</p> <p>3.2 Variants of FSB 26</p> <p>3.3 Two Case studies 27</p> <p>3.4 Application of FSB and Its Variants in Industry 35</p> <p>3.5 Summary and Future Directions 35</p> <p>References 36</p> <p><b>4 Fundamentals of Friction Stir Processing 39<br /> </b><i>Atul Kumar, Devasri Fuloria, Manu Srivastava, and Sandeep Rathee</i></p> <p>4.1 Friction Stir Processing (FSP): Background 39</p> <p>4.2 Working Principle of FSP 39</p> <p>4.3 Comparison with Other Severe Plastic Deformation (SPD) Techniques 42</p> <p>4.4 Process Variables 43</p> <p>4.5 Mechanisms of Microstructural Evolution During FSP 48</p> <p>4.6 Critical Issues in FSP 49</p> <p>4.7 Future Scope 50</p> <p>References 51</p> <p><b>5 Role of FSP in Surface Engineering 55<br /> </b><i>Setu Suman and Kazi Sabiruddin</i></p> <p>5.1 Introduction 55</p> <p>5.2 Role of Surface Modification Techniques 56</p> <p>5.3 Thermal Spray Technique 57</p> <p>5.4 FSP – Solid-State Coating Process 58</p> <p>5.5 Process Parameters of FSP: Surface Engineering 60</p> <p>5.6 Inappropriate Characteristics of Surface Modification 61</p> <p>5.7 Summary 63</p> <p>References 64</p> <p><b>6 Surface Composite Fabrication Using FSP 67<br /> </b><i>Baidehish Sahoo, Jinu Paul, and Abhishek Sharma</i></p> <p>6.1 Introduction 67</p> <p>6.2 Reinforcement Incorporation Approaches 68</p> <p>6.3 Effect of Process Parameters 71</p> <p>6.4 Microstructural Evolution and Mechanical Properties 75</p> <p>6.5 Strengthening Mechanisms 80</p> <p>6.6 Defects 83</p> <p>6.7 Summary and Future Directions 86</p> <p>References 86</p> <p><b>7 Friction Stir Welding of Dissimilar Metals 93<br /> </b><i>Narayan Sahadu Khemnar, Yogesh Ramrao Gunjal, Vijay Shivaji Gadakh, and Amrut Shrikant Mulay</i></p> <p>7.1 Introduction 93</p> <p>7.2 Application Areas of Dissimilar Material Joining 94</p> <p>7.3 Issues for Dissimilar Material Joining 94</p> <p>7.4 FSW of Dissimilar Materials 95</p> <p>7.5 Recent Developments in Tool Design and Tool Materials 103</p> <p>7.6 Parameter Optimization 103</p> <p>7.7 Common Defects that Occur in FSW of Dissimilar Metal Joining 104</p> <p>7.8 Future Recommendations for Dissimilar Metal Joining 105</p> <p>Acknowledgments 105</p> <p>References 106</p> <p><b>8 Friction Stir Welding of Aluminum and Its Alloy 109<br /> </b><i>Palani Sivaprakasam, Kolar Deepak, Durairaj Raja Joseph, Melaku Desta, Putti Venkata Siva Teja, and Murugan Srinivasan</i></p> <p>8.1 Introduction 109</p> <p>8.2 Fundamentals of FSW 110</p> <p>8.3 FSW of Aluminum and Its Alloy 110</p> <p>8.4 Influences of Process Parameters 112</p> <p>8.5 Testing and Characterization of FSW of Al and Its Alloy 115</p> <p>8.6 Additive Mixed Friction Stir Process of Al and Its Alloy 118</p> <p>8.7 Applications 118</p> <p>8.8 Conclusions 119</p> <p>References 119</p> <p><b>9 Mechanical Characterization of FSWed Joints of Dissimilar Aluminum Alloys of AA 7050 and AA6082</b> <b>125</b><br /> <i>Mohd Sajid, Gaurav Kumar, Husain Mehdi, and Mukesh Kumar</i></p> <p>9.1 Introduction 125</p> <p>9.2 Materials and Methods 126</p> <p>9.3 Results and Discussion 127</p> <p>References 131</p> <p><b>10 Sample Preparation and Microstructural Characterization of Friction Stir Processed Surface Composites 135</b><br /> <i>Manu Srivastava, Sandeep Rathee, Shazman Nabi, and Atul Kumar</i></p> <p>10.1 Introduction 135</p> <p>10.2 Sample Preparation for Microscopic Analysis of Metals, Alloys, and Composites 136</p> <p>10.3 Etching 140</p> <p>10.4 Microstructural Evolution 141</p> <p>Acknowledgment 146</p> <p>References 146</p> <p><b>11 Microstructural Characterization and Mechanical Testing of FSWed/FSPed Samples 149</b><br /> <i>Prem Sagar, Sushma Sangwan, and Mohankumar Ashok Kumar</i></p> <p>11.1 Introduction 149</p> <p>11.2 Microstructural Characterization 152</p> <p>11.3 Mechanical Testing 159</p> <p>11.4 Conclusions 162</p> <p>References 162</p> <p><b>12 Comparative Analysis of Microstructural and Mechanical Characteristics of Reinforced FSW Welds 165</b><br /> <i>Tanvir Singh</i></p> <p>12.1 Introduction 165</p> <p>12.2 Friction Stir Welding (FSW) 166</p> <p>12.3 Reinforcing Materials-Based Fabrication of FSW Welds 167</p> <p>12.4 Joinability of Reinforced FSW Welds 168</p> <p>12.5 Metallurgical Characteristics of FSW Reinforced Welds 169</p> <p>12.6 Mechanical Behavior of Reinforced FSW Welds 179</p> <p>12.7 Conclusions 184</p> <p>12.8 Future Challenges 184</p> <p>References 185</p> <p><b>13 Summary of Efforts in Manufacturing of Sandwich Sheets by Various Joining Methods Including Solid-State Joining Method 193<br /> </b><i>Divya Sachan, R. Ganesh Narayanan, and Arshad N. Siddiquee</i></p> <p>13.1 Introduction 193</p> <p>13.2 Sandwich Sheets 193</p> <p>13.3 Classification of Sandwich Sheet Structures 194</p> <p>13.4 Applications 195</p> <p>13.5 Fabrication Methods 196</p> <p>13.6 Summary 200</p> <p>References 201</p> <p><b>14 Defects in Friction Stir Welding and its Variant Processes 205<br /> </b><i>Vinayak Malik and Satish V. Kailas</i></p> <p>14.1 Introduction 205</p> <p>14.2 General Defects in FSW 205</p> <p>14.3 Characteristic Defects in Friction Stir Butt and Lap Joints 208</p> <p>14.4 Distinctive Defects in Major Friction Stir Variants 209</p> <p>14.5 Solutions to Avoid Defects in Friction Stir-Based Processes 212</p> <p>14.6 Summary and Concluding Remarks 213</p> <p>Acknowledgment 213</p> <p>References 213</p> <p><b>15 Nondestructive Ultrasonic Inspections, Evaluations, and Monitoring in FSW/FSP 215<br /> </b><i>Yuqi Jin, Teng Yang, Narendra B. Dahotre, and Tianhao Wang</i></p> <p>15.1 Introduction 215</p> <p>15.2 Ultrasonic Wave Behaviors in FSWed/FSPed Samples 215</p> <p>15.3 Common Ultrasonic Inspection and Evaluation Methods for FSWed/FSPed Samples 224</p> <p>15.4 Case Studies on Recent Novel Ultrasound Evaluation and Monitoring in FSW/FSP 234</p> <p>15.5 Roles and Potentials of Ultrasound in Future FSW/FSP 242</p> <p>15.6 Conclusion 243</p> <p>Acknowledgment 243</p> <p>References 243</p> <p><b>16 Applications of Friction Stir Welding 245<br /> </b><i>Raja Gunasekaran, Velu Kaliyannan Gobinath, Kandasamy Suganeswaran, Nagarajan Nithyavathy, and Shanmugam Arun Kumar</i></p> <p>16.1 Introduction 245</p> <p>16.2 Application of FSW on Different Materials 247</p> <p>16.3 Industrial Applications of FSW 252</p> <p>16.4 Conclusion 255</p> <p>References 256</p> <p><b>17 Equipment Used During FSP 259<br /> </b><i>Kandasamy Suganeswaran, Nagarajan Nithyavathy, Palaniappan Muthukumar, Shanmugam Arunkumar, and Velu Kaliyannan Gobinath</i></p> <p>17.1 Introduction 259</p> <p>17.2 FSP Experimental Setup 264</p> <p>17.3 Microstructural Characterization 267</p> <p>17.4 Mechanical Behavior of Composites Based on Various Tool Shapes 271</p> <p>17.5 Mechanical behavior of Composites Based on Various Process Parameters 272</p> <p>17.6 Conclusion 273</p> <p>References 273</p> <p><b>18 Analysis of Friction Stir Welding Tool Using Various Threaded Pin Profiles: A Case Study 275<br /> </b><i>Bommana B. Abhignya, Ashish Yadav, Manu Srivastava, and Sandeep Rathee</i></p> <p>18.1 Introduction 275</p> <p>18.2 Geometry Considered 277</p> <p>18.3 Results and Discussions – Analysis in ANSYS 278</p> <p>18.4 Conclusion 279</p> <p>Acknowledgement 281</p> <p>References 281</p> <p><b>19 Static Structural and Thermal Analysis of Honeycomb Structure Fabricated by Friction Stir Processing Route: A Case Study 283<br /> </b><i>Nikhil Jaiswal, Umashankar Bharti, Ashish Yadav, Manu Srivastava, and Sandeep Rathee</i></p> <p>19.1 Introduction 283</p> <p>19.2 Modeling Details 284</p> <p>19.3 Result and Analysis 286</p> <p>19.4 Scope of the Case Study 290</p> <p>19.5 Conclusion 291</p> <p>Acknowledgement 292</p> <p>References 292</p> <p><b>20 Friction Stir-Based Additive Manufacturing 293<br /> </b><i>Ardula G. Rao and Neelam Meena</i></p> <p>20.1 Additive Manufacturing: An Introduction 293</p> <p>20.2 Solid-State AM Processes 295</p> <p>20.3 Case Studies of FSAM on Different Materials 299</p> <p>20.4 Advantages of FSAM Over Other AM Techniques 300</p> <p>20.5 Advancements 301</p> <p>20.6 Limitations 302</p> <p>20.7 Conclusions and Future prospectives 303</p> <p>References 303</p> <p>Index 307</p>

<p><b>Sandeep Rathee, PhD, </b>is an Assistant Professor in the Department of Mechanical Engineering at the National Institute of Technology, Srinagar, India. His research interests include friction stir welding/processing, additive manufacturing, composites, and hybrid manufacturing. <p><b>Manu Srivastava, PhD, </b>is an Assistant Professor in the Department of Mechanical Engineering at the PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, India. Her research interests include additive manufacturing, friction-based AM, friction stir processing, advanced materials, manufacturing practices, and optimization techniques. <p><b>J. Paulo Davim, PhD, </b>is a Professor at the University of Aveiro, Portugal and a Fellow (FIET) of the Institution of Engineering and Technology, UK. His research interests include advanced manufacturing methods and materials.

<p> <b>Understand the future of solid-state welding with this essential reference</b> <p>Techniques for material joining and surface modification are among the most important parts of engineering, particularly in structurally demanding industries like aerospace, defense, automotive, and marine manufacturing. Friction stir welding and processing (FSW/FSP) is a groundbreaking new solid-state welding and processing technology that has already begun to revolutionize these fields and many others. Still in the relatively early stages of research and development, FSW/FSP promises to be an essential area of study for engineers and designers across the manufacturing world. <p><i>Friction Stir Welding and Processing: Fundamentals to Advancements </i>provides an accessible but systematic overview of this technology and its likely future development. Beginning with an introduction to the foundational concepts of FSW/FSP, the book surveys various friction techniques, the key technologies and equipment, testing practices, and more. The result serves as a one-stop reference for readers looking to familiarize themselves with this cutting-edge technology. <p><i>Friction Stir Welding and Processing </i>readers will also find: <ul><li>A multinational authorial team of leaders in research and production </li><li>Detailed discussion of topics including forming and extrusion, riveting, cladding, surface composites, and more </li><li>Additional information on subjects like additive manufacturing and economics of production</li></ul> <p><i>Friction Stir Welding and Processing </i>will be of interest to scholars, researchers, academicians, industry practitioners, government labs, libraries, and anyone interested in the area of solid-state joining and processing.

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