A Comprehensive Review of Friction Stir Additive Manufacturing (FSAM) of Non-Ferrous Alloys

Additive manufacturing is a key component of the fourth industrial revolution (IR4.0) that has received increased attention over the last three decades. Metal additive manufacturing is broadly classified into two types: melting-based additive manufacturing and solid-state additive manufacturing. Friction stir additive manufacturing (FSAM) is a subset of solid-state additive manufacturing that produces big area multi-layered components through plate addition fashion using the friction stir welding (FSW) concept. Because of the solid-state process in nature, the part produced has equiaxed grain structure, which leads to better mechanical properties with less residual stresses and solidification defects when compared to existing melting-based additive manufacturing processes. The current review article intends to highlight the working principle and previous research conducted by various research groups using FSAM as an emerging material synthesizing technique. The summary of affecting process parameters and defects claimed for different research materials is discussed in detail based on open access experimental data. Mechanical properties such as microhardness and tensile strength, as well as microstructural properties such as grain refinement and morphology, are summarized in comparison to the base material. Furthermore, the viability and potential application of FSAM, as well as its current academic research status with technology readiness level and future recommendations are discussed meticulously.