Review of friction stir-based solid-state additive remanufacturing technology for steel materials

Steel materials are widely used in the field of infrastructure and equipment manufacturing. As the service life of components gradually extends, damages such as wear, cracks and corrosion are inevitable, leading to material performance degradation and even structural failure. Additive remanufacturing technology, characterized by rapid prototyping, high material utilization, and controllable repairing precision, offers a new method for materials repair and life extension. Friction stir-based additive manufacturing, built on the principle of friction stir welding, utilizes frictional heat and plastic deformation to achieve layer-by-layer material deposition. It has the advantages of low heat input, high compactness, low residual stress, superior mechanical properties, high efficiency and environmental friendliness. As a novel solid-state additive manufacturing technology, it avoids defects common in melt-based additive manufacturing, such as porosity, cracks and element vaporization. Consequently, it attracts more attention for the repair and remanufacturing of metal components. In this paper, principle, characteristics and process classifications of friction stir-based solid-state additive manufacturing are elaborated. And current research status of friction stir-based solid-state additive remanufacturing technology for steel materials are summarized. Finally, potential industrial application scenarios and future development directions are discussed.