ASPECTS REGARDING FRICTION STIR PROCESSING IN TWO WORKING MEDIUMS OF EN AC 5083 CAST ALUMINUM ALLOY

Authors

  • Lia-Nicoleta Boțilă National R&D Institute for Welding and Material Testing - ISIM Timisoara
  • Ion-Aurel Perianu National R&D Institute for Welding and Material Testing - ISIM Timisoara
  • Iuliana Duma National R&D Institute for Welding and Material Testing - ISIM Timisoara
  • Gabriela-Victoria Mnerie National R&D Institute for Welding and Material Testing - ISIM Timisoara

Keywords:

friction stir processing FSP, submerged friction stir processing SFSP, EN AC 5083 cast aluminum alloy, experiments, structural analysis, mechanical properties

Abstract

One of the materials processing processes, currently in use by researchers and at an international industrial level, is Friction Stir Processing (FSP), an innovative solid-state processing process for the surfaces of metallic materials, developed from the friction stir welding process FSW. The FSP process is environmentally friendly and versatile, used for local processing, on well-defined areas, of the surfaces of metallic materials used in various applications. An interesting FSP processing method is the one in which the process takes place in a liquid working medium. Due to the water used as a working medium, the process temperature can be better controlled, avoiding excessive heating of the processing tool and the material to be processed, thus increasing the service life of the processing tool. Cast aluminum alloys are found in various industrial applications. The cast aluminum alloy EN AC 5083 has good mechanical properties, corrosion and chemical resistance, with applicability in the shipbuilding, aeronautics, automotive, chemical industries, etc. The paper presents results of experimental research carried out at ISIM Timișoara on friction stir processing in two different working mediums (underwater - SFSP and in ambient environment - FSP), in one pass and in multiple passes, of the cast aluminum alloy EN AC 5083 of 5 mm thickness. A comparison of the results obtained after evaluating the processed material by visual examination, with penetrating radiation, structural analysis, mechanical tensile and static bending tests is also presented, these being more favorable in underwater processing conditions.

References

1. El Zathry, N.E., Akinlabi, S. et al., Friction Stir Based Techniques: An Overview, Welding in the World Vol.69, pp.327–361 (2025),

https://doi.org/10.1007/s40194-024-01847-w;

2. Ma, Z.Y., Feng A.H. et al., Recent Advances in Friction Stir Welding/processing of aluminum Alloys, Microstructural Evolution and Mechanical Properties, Crit. Rev. Solid State Mater. Sci. Vol. 43, No. 4, pp. 269-333 (2017),

https://doi.org/10.1080/10408436.2017.1358145

3. El-Sayed, M.M., Shash, A.Y., Abd-Rabou, M. et al., Welding and processing of metallic materials by using friction stir technique: A review, J. Adv. Join. Process., Vol. 3, 100059, (2021), https://doi.org/10.1016/j.jajp.2021.100059;

4. Kumar, R.A. et al., Review of friction stir processing of aluminium alloys, Mater. Today Proc., Vol.16, pp. 1048–1054, (2019), https://doi.org/10.1016/j.matpr.2019.05.194;

5. Li, K., Liu, X. and Zhao, Y., Research status and prospect of friction stir processing technology, Coatings, Vol. 9, pp. 129, (2019), doi:10.3390/coatings9020129;

6. Maurya, M. et al., Variants of friction stir based processes: review on process fundamentals, material attributes and mechanical properties, Materials Testing, Vol.66, No. 2, pp. 271-287, (2024), https://doi.org/10.1515/mt-2023-0196;

7. Heidarzadeh, A., Mironov, S., Kaibyshev, R. et al., Friction stir welding/processing of metals and alloys: A comprehensive review on microstructural evolution, Prog. Mater. Sci., Vol. 117, 100752, (2021), https://doi.org/10.1016/j.pmatsci.2020.100752;

8. Patel, V., Li, W., Vairis, A. et al., Recent Development in Friction Stir Processing as a Solid-State Grain Refinement Technique: Microstructural Evolution and Property Enhancement, Crit. Rev. Solid State Mater. Sci. Vol. 44, pp. 378–426, (2019), https://doi.org/10.1080/10408436.2018.1490251

9. Srivastava, A.K. et al., 20th Century Uninterrupted Growth in Friction Stir Processing of Lightweight Composites and Alloys, Mater. Chem. Phys., Vol. 266, 124572, (2021), https://doi.org/10.1016/j.matchemphys.2021.124572

10. Msomi, V., Fabrication of Metal Matrix Composites using the Submerged Friction Stir Processing Technique: A Recent Progress Review, Eng. Technol. Appl. Sci. Res., Vol.14, No.5, pp. 17256-17260 (2024), https://doi.org/10.48084/etasr.8255;

11. Silvestri, A.T, El Hassanin, A., De Alteriis, G., Astarita, A., Energy Consumption and Tool Condition in Friction Stir processing of Aluminum Alloys, Int. J. Precis. Eng. Manuf. – Green Technol., Vol.12, pp.1-18, (2025), https://doi.org/10.1007/s40684-024-00633-9;

12. Patel, M.S., Immanuel, R.J., Rahaman, A. et. al., Critical Review of Advanced Cooling Strategies in Friction Stir Processing for Microstructural Control, Crystals, Vol.14, pp. 655, (2024), https://doi.org/10.3390/cryst14070655;

13. Datta, A. et al., Application of Friction Stir Processing for Generating Novel Engineering Parts—A Review. In: Sahoo, P., Barman, T.K. (eds) Advances in Materials, Manufacturing and Design. INCOM 2024, Lect. Notes Mech. Eng., https://doi.org/10.1007/978-981-97-6667-3_38;

14. Marazani, T. et al., Mass flash reduction strategies in friction stir processing of aluminum alloys: A review. Engineering Reports, Vol. 6, No. 10, (2024), https://doi.org/10.1002/eng2.12981;

15. Iwaszko, J., New Trends in Friction Stir Processing: Rapid Cooling – a Review, Trans. Indian Inst. Met., Vol. 75, pp.1681-1693, (2022), https://doi.org/10.1007/s12666-022-02552-2;

16. Oancă, O., Sîrbu, N.A., Binchiciu, E.F., Mnerie, G.V., Perianu I.A., Method and technologies Functional Constructive Configuration Concept of a Flexible Unconventional Hybrid FSW-US Welding Process, Adv. Mater. Res., Vol.1153, pp.85-91, (2019),

https://doi.org/10.4028/www.scientific.net/AMR.1153.85

17. Perianu, I.A., Murariu, A.C. et al., Advancements in abrasive waterjet cutting technologies: A comprehensive overview and future prospects in the manufacturing technology, KEM, Vol.996, pp.77-86, (2024), https://doi.org/10.4028/p-Zr0osO;

18. Murariu, A.C., Non-destructive and mechanical tests for quality evaluation of friction stir welding joints, Welding & Materials Testing, Vol.1, pp11-15, (2020), https://www.bid-isim.ro/bid_arhiva/bid2020/bid1_2020_11-15.pdf;

19. El-Attara, T. et al., Friction Stir Processing: A Novel Approach for Strengthening and Surface Engineering, Benha Journal of Engineering Science and Technology, BJEST, Vol. 2, Issue 1, pp: 9-24, (2025),DOI:10.21608/bjest.2025.445848;

20. Akbari, M., DebRoy, T., Asadi, P., Sadowski, T., Recent advances in friction stir welding/processing tools, J. Manuf. Process., Vol.142, pp. 99-156, (2025), https://doi.org/10.1016/j.jmapro.2025.03.089;

Downloads

Published

2026-03-31

How to Cite

ASPECTS REGARDING FRICTION STIR PROCESSING IN TWO WORKING MEDIUMS OF EN AC 5083 CAST ALUMINUM ALLOY . (2026). Nonconventional Technologies Review, 30(1). https://revtn.ro/index.php/revtn/article/view/601

Most read articles by the same author(s)