Material flow and channel geometry evolution during friction stir channeling process – Impact of tool geometry and process parameters

The capability of manufacturing controlled and uniform geometry of channels is critical for potential application of friction stir channeling in thermal systems. The channel geometry is governed by the material flow around the tool during the channeling process. The heat generation and material flow are closely dependent on the friction stir channeling parameters (tool geometry and process parameters). In the present investigation the interrelation between the friction stir channeling parameters with material flow and channel geometry is analysed. The channel geometry is found to be function of tool geometry for constant process parameters. The channel area and height increase with reduction in the pin diameter, the shoulder diameter and with increase in the pin length. The process parameters govern the channel geometry for constant tool geometry. The increase in tool rotation speed, and reduction in tool travel speed and shoulder clearance resulted in reduction in channel area and height.