New friction stir techniques for dissimilar materials processing

Friction stir processing has been mainly used as a solid state joining process for similar or near similar materials. Now there are new, emerging applications for friction stir such as modifying the surface properties of the work material (friction stir surface modification), transferring material from the end of a consumable tool (friction surfacing) and forcing the work material into useful shapes (friction stir forming). Here we show a new direction in friction stir processing of forming and consumable tool deposition. The friction stir forming and friction surfacing methods show potential for dissimilar material joining and coating, respectively.