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The need for lightweight metals has directed attention towards the use of bimetallicBimetallic components, which combine two distinct material properties into a single component. A novel method known as friction stir backward extrusionFriction stir backward extrusion (FSBE) has been introduced for bimetallicBimetallic (steel-aluminumAluminum) tubular components fabrication. This method can be adopted for the fabrication of bimetallicBimetallic rings, which are subjected to compressive and shear loads during operation. Thus, it is essential that the bimetallicBimetallic ring should have enough ductility and bonding strength to withstand compressive, shear, and flexural loads without delamination. For this purpose, the interface bonding was evaluated through flatteningFlattening, pushout, and bendingBending tests. Where the flatteningFlattening process was simulated using Deform 3D to understand the separation between the cladded layer and tube. The results show that bonding between the substrate and claddingCladding material is the combined action of heat and pressure, as well as reduces the hardnessHardness of the cladded layer compared to base aluminumAluminum, which enhances the ductility and allows it to undergo significant plastic deformation without any fracture.

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Lightweight Bimetallic Tubular Components via Friction Stir Backward Extrusion: Fabrication and Process Outcome Analysis

  • 会议论文

  • 发表日期：

    2025年

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  • Rishabh Swarnkar,
  • Surjya K. Pal

摘要

The need for lightweight metals has directed attention towards the use of bimetallicBimetallic components, which combine two distinct material properties into a single component. A novel method known as friction stir backward extrusionFriction stir backward extrusion (FSBE) has been introduced for bimetallicBimetallic (steel-aluminumAluminum) tubular components fabrication. This method can be adopted for the fabrication of bimetallicBimetallic rings, which are subjected to compressive and shear loads during operation. Thus, it is essential that the bimetallicBimetallic ring should have enough ductility and bonding strength to withstand compressive, shear, and flexural loads without delamination. For this purpose, the interface bonding was evaluated through flatteningFlattening, pushout, and bendingBending tests. Where the flatteningFlattening process was simulated using Deform 3D to understand the separation between the cladded layer and tube. The results show that bonding between the substrate and claddingCladding material is the combined action of heat and pressure, as well as reduces the hardnessHardness of the cladded layer compared to base aluminumAluminum, which enhances the ductility and allows it to undergo significant plastic deformation without any fracture.