REVIEW article
Front. Mech. Eng.
Sec. Solid and Structural Mechanics
Volume 11 - 2025 | doi: 10.3389/fmech.2025.1656081
Enhanced Mechanical Properties of AA7075 Alloy through Friction Stir Processing: A Review
Provisionally accepted
- 1Gazi University, Ankara, Türkiye
- 2Smt Kashibai Navale College of Engineering Vadgaon, Pune, India
- 3Vishwakarma Institute of Technology, Pune, India
- 4Dr Vishwanath Karad MIT World Peace University, Pune, India
- 5Tolani Maritime Institute, Talegaon Dabhade, India
- 6Datta Meghe College of Engineering, Mumbai, India
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A friction stir-based material processing technique for improving the surface and microstructural characteristics of materials is called friction stir processing (FSP). Because FSP involves severe deformation caused by plasticity, material flow, heat transport, and microstructure evolution, it is a multiphysics problem that can be difficult to describe. The performance of process of friction stir is influenced by several factors, including plastic deformation, material flow, temperature, and residual stresses.Enhancing the process requires developing a numerical model that considers these influencing parameters for a specific work piece material. Lightweight materials such as aluminum alloys offer high specific strength and ductility, making them ideal for applications in the automotive and aerospace industries.Today's industries are primarily interested in metallic alloys that are lightweight and strong. Because of their low weight, aluminum alloys hold a special place in industry. Much effort is being made to improve the mechanical qualities of aluminum through a surface modification technique called friction stir processing. This study reviews the literature on the friction stir processing of AA7075 alloy, focusing on the influence of key parameters such as rotational speed, traverse speed, and machining conditions.Modeling and simulations of FSP for material change have not been extensively studied. This study uses ABAQUS/Explicit to create a computationally efficient process model based on the coupled Eulerian-Lagrangian (CEL) formulation in order to simulate the FSP of aluminum alloy. Tool plunging, dwelling, and stirring phases are all included in the simulation of the full FSP process using the three-dimensional (3D) finite element model. The impact of tool-rotational speed and tool pin profile during the FSP process is assessed using simulations. Comparing the proposed model's computational efficiency to other models currently in use for friction stir-welding procedures is another way to assess its effectiveness. In order to validate the model, the FSP experiment is conducted using temperature and process force measurements.This work shows that the CEL model can be a useful numerical tool for simulating complex process mechanics and optimizing FSP process parameters for industrial applications.
Keywords: Lightweight materials, Friction stir process, coupled Eulerian-Lagrangian, AA7075 alloy, Abaqus
Received: 29 Jun 2025; Accepted: 18 Aug 2025.
Copyright: © 2025 Salunkhe, Patil, Washimkar, Pawar, Naidu and Shinde. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
* Correspondence: Sachin Salunkhe, Gazi University, Ankara, Türkiye
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