Friction stir-assisted cladding: Solid-state recycling of machine shop scrap for sustainable metal production Pankaj KAUSHIK Materials Research Proceedings, 2024 The manufacturing industry, a cornerstone of modern economies, generates a substantial amount of waste in the form of manufacturing chips, which often end up as discarded byproducts. This waste not only poses environmental hazards but also represents a missed opportunity for resource efficiency and cost savings. This article explores the innovative use of friction stir-assisted cladding (FS-AC) as a sustainable and cost-effective solution for repurposing aluminum chips on a steel substrate without melting the material. The study investigates the mechanism of the FS-AC process, highlighting the conversion of metallic swarf into a feedstock material for cladding without entailing costly clad materials. Metallographic analysis demonstrates a uniformly clad layer with an average thickness of 0.95 mm. The study addresses challenges related to bonding at the clad layer-substrate interface and proposes further advanced characterization studies for diffusion analysis and coating-substrate bond strength. In conclusion, the FS-AC process presents a valuable method for recycling machine shop floor scrap, transforming it into useful feedstock material for cladding purposes, and that too in an energy-efficient manner. This proposed approach has promising potential for processing different material combinations for additive manufacturing and exploring functionally graded material development using metallic swarf.
Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel Pankaj Kaushik, Dheerendra Kumar Dwivedi Materials and Manufacturing Processes, 2023 Joining two dissimilar materials, like aluminum and steel, has been a topic of great importance in modern engineering applications. Therefore, this research expounds on joining aluminum alloy (Al5052) with low-carbon mild steel using friction stir welding. A novel approach is employed that quantifies the discontinuities (steel debris and voids) in the weld stir zone using image analysis. Furthermore, a parametric investigation was conducted following a full factorial approach with three tool rotational and traverse speed levels, and a heat input factor (ω2/v) was derived through theoretical modeling of process parameters. The heat input factor was substantiated experimentally with thermal cycle measurements. Results revealed that both the ω2/v factor and the extent of discontinuities determined the soundness and strength of the weld joints. A low rotational speed of 386 revolutions/minute and moderate traverse speed of 140 mm/minute, having minimal discontinuities, rendered maximum joint strength of approximately 212 MPa.
Developing double hook morphology in Al–steel FSSW via controlled pin penetration P Kaushik, DK Dwivedi Journal of Adhesion Science and Technology, 1-20 , 2025 2025
Comprehensive analysis of friction stir welding of high-temperature P22 steel and Al 5052 alloy: metallurgical mixing, mechanical properties, and failure mechanism P Kaushik, DK Dwivedi Welding in the World 69 (2025), 1991-2002 , 2025 2025 Citations: 6
Exit hole refilling in aluminum steel FSSW joints using Fe–Zn powder P Kaushik, DK Dwivedi International Conference on Design and Manufacturing Technologies, 911-918 , 2024 2024 Citations: 1
Investigating the influence of stress ratio variation on the crack growth rate in friction stir welded dissimilar aluminum alloys S Tiwari, S Verma, P Kaushik Engineering Failure Analysis 165, 108828 , 2024 2024 Citations: 11
Investigating failure in laser-welded joints of microalloyed steel: a systematic review DK Saini, P Kaushik Transactions of the Indian Institute of Metals 77 (8), 1939-1957 , 2024 2024 Citations: 3
Friction stir-assisted cladding: Solid-state recycling of machine shop scrap for sustainable metal production P KAUSHIK, PP DATE Materials Research Proceedings 41 (2024), 2822-2828 , 2024 2024 Citations: 1
Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel P Kaushik, D Kumar Dwivedi Materials and Manufacturing Processes 39 (2), 161-173 , 2024 2024 Citations: 29
Enhancing strength and metallurgical soundness of dissimilar Al-steel FSSW joints through novel exit hole refilling technique P Kaushik, DK Dwivedi Manufacturing Letters 38, 83-87 , 2023 2023 Citations: 8
Significance of Tool Geometry and Double Hook Formation in Al-Steel Dissimilar Friction Stir Spot Joints P Kaushik, DK Dwivedi THE 76th IIW ANNUAL ASSEMBLY AND INTERNATIONAL CONFERENCE ON WELDING AND … , 2023 2023 Citations: 2
Dissimilar metal joining of steel-aluminium alloy by friction stir welding DK Dwivedi Dissimilar Metal Joining, 269-285 , 2023 2023 Citations: 2
Investigating the effects of induction heating on friction stir welding of low-carbon steel P Kaushik, R Singh, A Jena, DK Dwivedi International Conference on Advances in Materials Processing: Challenges and … , 2022 2022 Citations: 2
Influence of hook geometry on failure mechanism of Al6061-galvanized steel dissimilar FSW lap joint P Kaushik, DK Dwivedi Archives of Civil and Mechanical Engineering 22 (4), 149 , 2022 2022 Citations: 19
Al-steel dissimilar joining: Challenges and opportunities P Kaushik, DK Dwivedi Materials Today: Proceedings 62, 6884-6899 , 2022 2022 Citations: 42
Effect of tool geometry in dissimilar Al-steel friction stir welding P Kaushik, DK Dwivedi Journal of Manufacturing Processes 68, 198-208 , 2021 2021 Citations: 104
Induction preheating in FSW of Al-Steel combination P Kaushik, DK Dwivedi Materials Today: Proceedings 46, 1091-1095 , 2021 2021 Citations: 28
MOST CITED SCHOLAR PUBLICATIONS
Effect of tool geometry in dissimilar Al-steel friction stir welding P Kaushik, DK Dwivedi Journal of Manufacturing Processes 68, 198-208 , 2021 2021 Citations: 104
Al-steel dissimilar joining: Challenges and opportunities P Kaushik, DK Dwivedi Materials Today: Proceedings 62, 6884-6899 , 2022 2022 Citations: 42
Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel P Kaushik, D Kumar Dwivedi Materials and Manufacturing Processes 39 (2), 161-173 , 2024 2024 Citations: 29
Induction preheating in FSW of Al-Steel combination P Kaushik, DK Dwivedi Materials Today: Proceedings 46, 1091-1095 , 2021 2021 Citations: 28
Influence of hook geometry on failure mechanism of Al6061-galvanized steel dissimilar FSW lap joint P Kaushik, DK Dwivedi Archives of Civil and Mechanical Engineering 22 (4), 149 , 2022 2022 Citations: 19
Investigating the influence of stress ratio variation on the crack growth rate in friction stir welded dissimilar aluminum alloys S Tiwari, S Verma, P Kaushik Engineering Failure Analysis 165, 108828 , 2024 2024 Citations: 11
Enhancing strength and metallurgical soundness of dissimilar Al-steel FSSW joints through novel exit hole refilling technique P Kaushik, DK Dwivedi Manufacturing Letters 38, 83-87 , 2023 2023 Citations: 8
Comprehensive analysis of friction stir welding of high-temperature P22 steel and Al 5052 alloy: metallurgical mixing, mechanical properties, and failure mechanism P Kaushik, DK Dwivedi Welding in the World 69 (2025), 1991-2002 , 2025 2025 Citations: 6
Investigating failure in laser-welded joints of microalloyed steel: a systematic review DK Saini, P Kaushik Transactions of the Indian Institute of Metals 77 (8), 1939-1957 , 2024 2024 Citations: 3
Significance of Tool Geometry and Double Hook Formation in Al-Steel Dissimilar Friction Stir Spot Joints P Kaushik, DK Dwivedi THE 76th IIW ANNUAL ASSEMBLY AND INTERNATIONAL CONFERENCE ON WELDING AND … , 2023 2023 Citations: 2
Dissimilar metal joining of steel-aluminium alloy by friction stir welding DK Dwivedi Dissimilar Metal Joining, 269-285 , 2023 2023 Citations: 2
Investigating the effects of induction heating on friction stir welding of low-carbon steel P Kaushik, R Singh, A Jena, DK Dwivedi International Conference on Advances in Materials Processing: Challenges and … , 2022 2022 Citations: 2
Exit hole refilling in aluminum steel FSSW joints using Fe–Zn powder P Kaushik, DK Dwivedi International Conference on Design and Manufacturing Technologies, 911-918 , 2024 2024 Citations: 1
Friction stir-assisted cladding: Solid-state recycling of machine shop scrap for sustainable metal production P KAUSHIK, PP DATE Materials Research Proceedings 41 (2024), 2822-2828 , 2024 2024 Citations: 1
Developing double hook morphology in Al–steel FSSW via controlled pin penetration P Kaushik, DK Dwivedi Journal of Adhesion Science and Technology, 1-20 , 2025 2025
