Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel
The direct energy deposition arc process is widely used for fabricating medium and large components with moderate geometric complexity but often results in coarse microstructures and inconsistent hardness. This study introduces a hybrid manufacturing approach combining the friction stir burnishing p...
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MDPI AG
2025-02-01
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| author | Teerayut Cordkaew Jun’ichi Kaneko Takeyuki Abe |
| author_facet | Teerayut Cordkaew Jun’ichi Kaneko Takeyuki Abe |
| author_sort | Teerayut Cordkaew |
| collection | DOAJ |
| description | The direct energy deposition arc process is widely used for fabricating medium and large components with moderate geometric complexity but often results in coarse microstructures and inconsistent hardness. This study introduces a hybrid manufacturing approach combining the friction stir burnishing process with the direct energy deposition arc by a gas–metal arc welding technique to refine the microstructure and enhance the microhardness of components fabricated from austenitic stainless steel 316L. Our former study used an aluminum alloy (A5052) friction stir burnishing tool, demonstrating significant microhardness improvement and grain refinement. However, it also faced notable challenges under high-heat and -friction conditions, including the effect of material adherence to the workpiece during processing. Therefore, this study introduces a newly developed friction stir burnishing tool made from copper (C1100) and compares its performance with the aluminum alloy tool regarding microhardness enhancement and microstructure refinement. The results indicate that the specimen processed by direct energy deposition arc combined with the copper friction stir burnishing tool demonstrated the best overall performance in grain refinement and hardness enhancement. Specifically, it achieved the highest average microhardness of 250 HV at 50 µm depths, compared to 240 HV for the aluminum alloy tool. The statistical analysis showed that both tools led to significant improvements over specimens processed without them. The statistical analysis confirmed a notable reduction in secondary dendrite arm spacing across all depths, with the copper tool demonstrating the most refinement. Additionally, a preliminary investigation of corrosion behavior revealed tool-dependent differences. Overall, this study offers a promising approach to improving additive manufacturing, particularly for industries with less stringent surface finish requirements. It could potentially reduce post-processing time and cost. Future research should explore different process parameters and assess long-term corrosion performance to develop this hybrid technique further. |
| format | Article |
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| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-02-01 |
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| spelling | doaj-art-f4b31df0baf14ea8932034ee12e50fbb2025-08-20T03:12:11ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-02-01925310.3390/jmmp9020053Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless SteelTeerayut Cordkaew0Jun’ichi Kaneko1Takeyuki Abe2Graduate School of Science and Engineering, Saitama University, 255 Shimo-Okubo, Sakura-ku, Saitama 338-8570, JapanGraduate School of Science and Engineering, Saitama University, 255 Shimo-Okubo, Sakura-ku, Saitama 338-8570, JapanGraduate School of Science and Engineering, Saitama University, 255 Shimo-Okubo, Sakura-ku, Saitama 338-8570, JapanThe direct energy deposition arc process is widely used for fabricating medium and large components with moderate geometric complexity but often results in coarse microstructures and inconsistent hardness. This study introduces a hybrid manufacturing approach combining the friction stir burnishing process with the direct energy deposition arc by a gas–metal arc welding technique to refine the microstructure and enhance the microhardness of components fabricated from austenitic stainless steel 316L. Our former study used an aluminum alloy (A5052) friction stir burnishing tool, demonstrating significant microhardness improvement and grain refinement. However, it also faced notable challenges under high-heat and -friction conditions, including the effect of material adherence to the workpiece during processing. Therefore, this study introduces a newly developed friction stir burnishing tool made from copper (C1100) and compares its performance with the aluminum alloy tool regarding microhardness enhancement and microstructure refinement. The results indicate that the specimen processed by direct energy deposition arc combined with the copper friction stir burnishing tool demonstrated the best overall performance in grain refinement and hardness enhancement. Specifically, it achieved the highest average microhardness of 250 HV at 50 µm depths, compared to 240 HV for the aluminum alloy tool. The statistical analysis showed that both tools led to significant improvements over specimens processed without them. The statistical analysis confirmed a notable reduction in secondary dendrite arm spacing across all depths, with the copper tool demonstrating the most refinement. Additionally, a preliminary investigation of corrosion behavior revealed tool-dependent differences. Overall, this study offers a promising approach to improving additive manufacturing, particularly for industries with less stringent surface finish requirements. It could potentially reduce post-processing time and cost. Future research should explore different process parameters and assess long-term corrosion performance to develop this hybrid technique further.https://www.mdpi.com/2504-4494/9/2/53directed energy depositionfriction stir burnishingaustenitic stainless steel 316Lmicrostructuremicrohardness |
| spellingShingle | Teerayut Cordkaew Jun’ichi Kaneko Takeyuki Abe Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel Journal of Manufacturing and Materials Processing directed energy deposition friction stir burnishing austenitic stainless steel 316L microstructure microhardness |
| title | Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel |
| title_full | Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel |
| title_fullStr | Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel |
| title_full_unstemmed | Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel |
| title_short | Comparison of Aluminum Alloy and Copper Friction Stir Burnishing Tools Combined with Direct Energy Deposition Arc Process on Microstructure and Microhardness of 316L Stainless Steel |
| title_sort | comparison of aluminum alloy and copper friction stir burnishing tools combined with direct energy deposition arc process on microstructure and microhardness of 316l stainless steel |
| topic | directed energy deposition friction stir burnishing austenitic stainless steel 316L microstructure microhardness |
| url | https://www.mdpi.com/2504-4494/9/2/53 |
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