Friction Stir Processing of Cast NiAl Bronze


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Friction stir processing (FSP) of cast NiAl bronze has resulted in significant increases in properties including more than doubling the yield greater that 40 percent increase in the threshold fatigue life; all achieved while increasing ductility. These and other strength, greater than a 60 percent increase in tensile strength, and property improvements were realized following studies of FSP procedures specifically for NiAl bronze. Within this manuscript, FSP procedures and other “lessons learned” are presented. Details of property improvements are documented elsewhere within this conference proceedings (see Fuller et al.). Presented herein are tool designs for efficient material flow, tool materials capable of long life at 1000°C, rastering procedures covering large surface areas, and other results pertinent to achieve improved properties in cast NiAl bronze following friction stir processing.



Materials Science Forum (Volumes 539-543)

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Edited by:

T. Chandra, K. Tsuzaki, M. Militzer , C. Ravindran




M. W. Mahoney et al., "Friction Stir Processing of Cast NiAl Bronze", Materials Science Forum, Vols. 539-543, pp. 3721-3726, 2007

Online since:

March 2007




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[2] M.P. Miles, M.W. Mahoney, T.W. Nelson, and R.S. Mishra, Finite Element Simulation of Plane-Strain Thick Plate Bending of Friction Stir Processed 2219 Aluminum, Friction Stir Welding and Processing II, Proceedings TMS Annual Meeting, San Diego, March 2003, pp.253-258.


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[5] P.B. Berbon, W.H. Bingel R.S. Mishra, C.C. Bampton, and M.W. Mahoney, Friction Stir Processing: A Tool to Homogenize Nanocomposite Aluminum Alloys, Scripta Mat., vol. 44 (2001), p.61.


[6] C. Fuller, M.W. Mahoney and W.H. Bingel, Friction Stir Processing of Aluminum Fusion Welds, 4 th Int. Symposium on Friction Stir Welding, Park City, Utah, USA, 14-16 May (2003).


[7] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Templesmith, and C.J. Dawes: Friction Stir Butt Welding, G.B. Patent Application No. 9125978. 8, Dec. 1991; U.S. Patent No. 5460317, Oct. (1995).

[8] M. Mahoney, W. Bingel, S. Sharma, and R. Mishra, Microstructural Modification and Resultant Properties of Friction Stir Processed Cast NiAl Bronze, Mater. Sci. Forum, Vols. 426-432 (2003) pp.2843-2848.


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[10] T. A. Marsico, PhD Thesis, Microstructural Development in Cast and Laser Beam Clad Nickel Aluminum Bronze, The Pennsylvania State University, August (1996).

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[13] S. Packer, T. Nelson, C. Sorensen, R. Steel, and M. Matsunaga, Tool and Equipment Requirements for Friction Stir Welding Ferrous and Other High Temperature Alloys, 4 th Int. Symposium on Friction Stir Welding, Park City, Utah, USA, 14-16 May (2003).


[14] M. Mahoney, Rockwell Scientific, Unpublished Research.

[15] C.B. Fuller, M. W. Mahoney, W. H. Bingel, M. Calabrese, and B. London, Tensile and Fatigue Properties of Friction Stir Processed NiAl Bronze, this proceedings.