Metal additive manufacturing using friction stir engineering: A review on microstructural evolution, tooling and design strategies

Abstract Solid state metal additive manufacturing (SS-MAM) techniques based on friction stir engineering (FSE) have gained significant attention since the last decade and act as a bridge for many existing MAM shortfalls. In this article, SS-MAM techniques based upon FSE especially additive friction stir (AFS) and friction stir additive manufacturing (FSAM) are discussed. There is meagre research with respect to tooling associated with these processes since they involve expertise in two fields i.e., AM and FSE. The current article bridges this gap with a detailed discussion on all relevant fundamentals of AFS and FSAM. The recent developments with respect to tooling design and parameters are discussed in-depth. Also, this article discusses metallurgy, microstructural aspects and mechanical properties of deposited layers via these techniques. A detailed timeline summarizing the development with respect to these techniques has been presented. A complete section is dedicated to utilization of these techniques for different applications. Recent developments and trends are also discussed in detail.

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