Employing Flaws Caused by FSP to Fabricate Miniaturized Channels

The ever-increasing complexity of modern high- performance components, weight and space limitations, and material savings in different industries have emphasized the necessity for more efficient heat dissipation compact parts. In this respect and due to world competition to achieve higher reliability and lower cost, design and manufacture of miniaturized cooling channels have been faced many challenges. One of the most innovative methods of mini and micro channels fabrication is based on Friction Stir Processing (FSP) which enables possibility of economical manufacturing of continuous and non-linear channels, without any requirement to access the part cross sections and also with no impact on part functionality. Friction Stir Channeling (FSC) is a modern method inspired by FSP that takes unique inherent advantages of cold plastic fabrication. FSC is created based of one of FSP common flow defects named wormhole defect, which accentuates the requirement of experimental investigation design, considering the material flow concepts. In the current research, three novel FSC tool designs have been proposed as the main affecting parameter of test strategy, theory behind each tool schematic has been described and the best design is highlighted exploring the hydraulic diameter and corresponding friction coefficient as a representation of channels flow resistance.