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Friction Stir Channeling

Friction stir channeling (FSC) is a new concept to produce integral channels in metallic materials. There are many applications where heat exchange is needed or desirable. The conventional approaches of building heat exchangers or incorporating fluid channels can be broadly divided in two groups. The first group would consist of use of tubes and joining processes, whereas the second group would involve machining of channels and joining of several pieces. FSC concept on the other hand can be used to create integral channels in a solid plate in one step. The shape and size of the channel can be controlled by the tool design as well as process parameters.

Friction Stir Processing for Enhanced Low-temperature Formability
Manufacturing of components from thick plates usually is done by joining, as bending and shaping is difficult because of limited ductility. In as FSP condition, aluminum alloys exhibit very high ductility. Mahoney et al. (2003) have used this to bend 1” thick 2519 Al plate with just a partial FSP layer on the tensile side. This would give designers added flexibility of shaping sheets and plates with localized enhanced formability. With low heat input from FSP, the region of reduced strength is very limited. In applications where some of the welded joints are replaced by bends, such design can lead to significantly higher performance.