Development and Transformation of Additive Friction Stir Technology from Concept to Commercialization, Leading AFS Division, Managing Intellectual Property Portfolio, Proposal Development and Setting-up of Basic Characterization Laboratory

Realizing the concept of Additive Friction Stir (AFS) technology as additive manufacturing, coating, surface composite manufacturing and joining process.AFS utilizes consumable filler stock in the form of solid/powder. The filler material is forced through the tool in the center of the tool while the custom designed tool coats/builds/joins based on the application.AFS is a solid state thermo-mechanical process like friction stir welding/processing and the AFS deposits have wrought microstructure with fine grains. AFS does not have pin/probe in the tool to penetrate into the base metal which reduces the tool complexity and tool material demands. The dynamic shape of filler material does the job while it being consumed when it is used as joining process.AFS finds numerous application in corrosion/wear resistant coating, microstructure gradient composite manufacturing, dissimilar metal joining, additive manufacturing, and repairing and reclamation.

Design and development on miniaturized materials testing machines, including fatigue and tensile testing machineFriction stir welding and processingSystem level analysis of hydrokinetic systems (renewable energy)

Science and technology friction stir welding and processingFSP/FSW tool designFSW/FSP of similar and dissimilar materialsDesign and development of experimental facilitySurface metal-matrix composites Eco-friendly energy harvesting from nature: hydrokinetic energyMaterial selection and manufacturingSystem level materials optimization based on performance, economics and reliabilitySystem level implementation of FSW/FSP PROJECTS AND ACTIVITIES; 1. Design and development of friction stir welding and processing tools2. Friction stir processing of hypo- and hypereutectic aluminum-silicon castingsRefining the silicon particle size to improve the merchantability components at localized positions for specific applicationsImproving the fracture toughnessRemoving the casting defects like poresModifying the cast microstructure into wrought microstructure in the localized positions3. Friction Stir Processing Mg-Y-REEnhancing the impact toughness by grain refinement below a critical limit and precipitate size control though heat treatment followed by friction stir processing Corrosion studies4. Friction stir surface meal matrix compositessynthesis of Al and Mg matrix surface composites with incorporation on SiC and B4C to prove the synergistic improvement mechanical properties Selective addition of chemical species in the surface to improve corrosion properties of Mg alloysAddition of ceramic particles in the surface of Mg alloys for energy dispersion during impact loading

Friction stir welding of similar and dissimilar metal welding, DRDO project, Ultra fine grain synthesis using FSP.

Quality Control, Raw Material Handling, Waste Minimization and Value Addition, Developments, Recuperation and Recovery, Furnace Control