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<p>Friction stir channeling (FSC) is a promising technique for creating subsurface channels in metallic materials, with potential applications in thermal management. While extensively studied for aluminum, its application to copper remains limited. This study investigates the FSC process on copper plates, focusing on the influence of process parameters on channel characteristics, microstructure, and mechanical properties. Channels were fabricated using a range of tool rotation speeds (515, 840, and 1200&#xa0;RPM) and shoulder-workpiece clearances (SWCs) (0.4, 0.8, and 1.2&#xa0;mm). Macroscopic analysis revealed that increasing rotation speed led to greater channel ceiling height, while an intermediate SWC of 0.8&#xa0;mm maximized channel area. Microstructural characterization using electron backscatter diffraction&#xa0;analysis showed grain refinement in the channel ceiling zone compared to the unprocessed zone, with significant variations in grain size and structure depending on the process parameters. Tensile testing demonstrated a reduction in strength for FSCed samples compared to the base material, with the highest tensile strength achieved at the lowest rotation speed. Both rotation speed and SWC significantly influenced tensile strength and microhardness. This study provides valuable insights into the FSC process for copper, advancing material processing knowledge and enabling its potential use in thermal management applications.</p>

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Characterization of Copper Channels Produced by Friction Stir Channeling: Influence of Process Parameters

  • 期刊论文

  • 发表日期：

    2025年4月14日

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  • Milap Pandya,
  • Nirav Patel,
  • Kush Mehta

摘要

Friction stir channeling (FSC) is a promising technique for creating subsurface channels in metallic materials, with potential applications in thermal management. While extensively studied for aluminum, its application to copper remains limited. This study investigates the FSC process on copper plates, focusing on the influence of process parameters on channel characteristics, microstructure, and mechanical properties. Channels were fabricated using a range of tool rotation speeds (515, 840, and 1200 RPM) and shoulder-workpiece clearances (SWCs) (0.4, 0.8, and 1.2 mm). Macroscopic analysis revealed that increasing rotation speed led to greater channel ceiling height, while an intermediate SWC of 0.8 mm maximized channel area. Microstructural characterization using electron backscatter diffraction analysis showed grain refinement in the channel ceiling zone compared to the unprocessed zone, with significant variations in grain size and structure depending on the process parameters. Tensile testing demonstrated a reduction in strength for FSCed samples compared to the base material, with the highest tensile strength achieved at the lowest rotation speed. Both rotation speed and SWC significantly influenced tensile strength and microhardness. This study provides valuable insights into the FSC process for copper, advancing material processing knowledge and enabling its potential use in thermal management applications.