Consolidation methods plastic forming

Common consolidation methods include variations on pressing powders, plastic forming, slip casting and tape casting. The choice of which method to use for a given application is very dependent upon the shape, size and required dimensional tolerances of the final product, available capital outlay and desired productivity. Each of these methods is examined in turn below, followed by sintering, which turns the consolidated powders into a monolithic body with mechanical integrity. 

Conventional friction stir spot welding leaves behind a keyhole (exit hole) after the weld has been done. In order to avoid this, GKSS of Germany invented a process that would fill the keyhole (Ref 4). This method was called the refill FSSW process. The joined region consists of a spot of material that has been plasticized, displaced in a process similar to a back extrusion, and then replaced, forming a fully consolidated weld that is nominally flush with the original surface. 

Reinforced Plastics. Reinforced plastics represent the most technologically advanced field of structural composites. They also have the broadest and most diverse range of applications. Fiber-reinforced plastics (FRPs) are divided into normal and advanced composites. The methods of working with each are very similar in many respects. The designation relates to the nature of the matrix and reinforcement materials and the tolerances required of the finished products. To create a fiber-reinforced plastic, an array of selected fiber reinforcement material is impregnated with a polymer resin and formed into a desired shape. The mass is then compacted to consolidate the fibers together as tightly as possible, and the matrix material polymerizes to form a solid mass about the reinforcement fibers. 

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