MANUFACTURING PROCESSES (MEFB213)

Lecturer Name:MR. ZUBAIDI FAIESAL BIN MOHAMAD RAFAAI

Assignment: FSW(FRICTION STIR WELDING)
Due Date: 1/9/2016

NAME:
ID NUMBER:

MALVEN MARK
ME093028

INTRODUCTION

Friction Stir Welding (FSW) invented and experimentally proven at The Welding
Institute UK in December 1991 . FSW is a type of solid state joining process that joins
two surface facing materials through heat produced by friction and mechanical pressure.
As shown in Figure below, a probe which is shorter than the weld depth required is
drilled into the butt joint of two materials that are clamped together . The probes
shoulder is now in contact with the surface of the work. At this interface, friction
producing heat is obtained when the probe and its shoulder starts rotating at specific rpm
which is predetermined by the type of material that is being welded. The heat produced
softens the surface of both the materials and also welds them together as the probe and its
shoulder is moved along the desired welding path while maintaining the same rotational
rpm.

TASK STATEMENT
This task was assigned for the purpose of encouraging students to explore the outside
world regarding the current advancement on manufacturing processes and also the latest
technologies used in companies and factories in the line of production.

TASK OBJECTIVE
Friction Stir Welding was chosen since it was found that this strategy for welding is
intriguing and valuable me as well as for the different generation in Malaysia. FSW could
be utilized as a part of the creation of my last year venture as this welding has been
demonstrated to indicate impressive diminishment in repair and re-work, low contortion,
and general gear adaptability. This sort of favorable circumstances is the thing that an
understudy, for example, I would search for in selecting a kind of assembling process
since it would spare time and permit me to concentrate on alternate parts of my task
without the need to stress over the nature of the last item.

Organizations, for example, HITACHI are utilizing Friction Stir Welding to shaping
joints that require high dependability, (for example, railroad vehicles and car component).
The explanation for this is on the grounds that FSW makes less changes to the states of
the areas in the wake of joining (contrasted with the disfigurement after ordinary
combination welding) and the quality of the joint is high. As an understudy, I find that it
would be awesome chance to satisfy my entry level position prerequisite furthermore
propel my profession way in organizations, for example, HITACHI due to brand
acknowledgment as well as an instructive ordeal to see and take in the Friction Stir
Welding process direct.

LITERATURE REVIEW

In the year 2016, numerous studies and trials have been completed, examining the
numerous parts of Friction Stir Welding. This prompted the distributions of numerous
diaries and additionally thesis materials that portray the numerous revelations made by
researchers and researchers with respect to this specific sort of welding. For instance, a
paper, distributed by Ho-Sung Lee and Kookil No in the tenth of June 2016, depicted
their examination with respect to the impacts of Friction Stir Welding on the mechanical
and micro-structure properties of Aluminum-Lithium alloy.Micro-structure is
characterized as a structure of a material whose scale has been amplified under a
microscope while mechanical properties is a term use to arrange properties, for example,
elasticity, compressive strength and fracture toughness.

This exploration clarifies that the motivation behind why Friction Stir Welding was
utilized to weld an aluminum-lithium compound is on the grounds that its capacity to join
metals with least dissolving keeps the danger of deformities found in combination welds,
for example, liquidation breaking, hardening splitting, or oxide arrangement. The
investigation conveyed by Ho-Sung Lee and Kookil No, was finished by warming the

aluminum-lithium materials to a specific arrangement of temperatures before

experiencing the FSW process to be joined together. The variable that was kept steady all
through this examination was the measurement of the aluminum-lithium amalgam

The micro-structure was then seen under an electron microscope and the temperature
perusing at different part of the material, which was experiencing welding, was taken.
Taking into account Figure below , it was found that the temperature perusing on the
propelling side was more prominent then the withdrawing side

This supports the aftereffects of micro-hardening at material's nugget zone. It was

likewise found that grain re-crystallization happens at welding joint, hence bringing
about the specific part of the material to display somewhat more prominent microhardness attributes than the first material. Figure below demonstrated as follows,
demonstrates the micro structure of the aluminum-lithium combination taken under
the electron microscope. The picture demonstrates the extent of the grain boundary at
different part of the welded work-piece. It additionally demonstrates that at the

propelling side of the piece zone, where the temperature was high, the grain
boundary seemed more extended contrasted with the other parts which bolsters the
theory that more drawn out grain size prompts less separation and in this manner
enhances the hardness of the material.

Another study was done regarding the examination of utilizing different pin
geometry of Friction Stir Welding to consolidate two different alloys, Aluminum alloy
and Magnesium alloy, through circular butt joint geometry . In this examination, it was
specified that four different sorts of pin geometry were utilized as a part of the welding
procedure to check whether there is any impacts on the weld strength at the welded joint
of the disparate alloys. Friction Stir Welding was chosen for this investigation in light of
the fact that the warmth created between the pin's shoulder and the surface of the material
as it pivots is sufficiently high to soften and consolidate the surface material and this lead
to plastic twisting which empowers re-crystallization. This trademark gives great
mechanical properties at the welded joint.Since no gasses are included in the Friction Stir
Welding process, it can be sorted as a green technology.

In any case, the nature of the joint shifts because of the numerous geometries of the

instrument. In this investigation, the sorts of pin utilized were cylindrical flute pin,
cylindrical threaded pin and cylindrical grooved pin.

The results of the experiment were determined by welding parameter. Welding

parameter is the ratio between the feed rate to the rotational speed of the pin which varies
for different tool geometries. In theory, the lower the value of the welding parameter, the
better the quality of flow around the tool pin. It was found that the cylindrical flute pin
had high welding parameter as it did not successfully weld the two alloy plates. The
cylindrical threaded pin, however, produced good quality weld and minimum surface
finish. The cylindrical grooved pin was found broken during the welding process as result
of heavy load on the z-axis.
The tensile strength of the welded circular butt joint was then tested using a
Universal Tensile Testing Machine and it was found that the tensile strength of the
welded joint can hold a tensile load range of 1310kg to 1320kg. It was concluded that
circular path welding involving different alloys can be achieved through Friction Stir
Welding by selecting the proper geometry pin tool and obtaining minimum feed rate to
rotational speed ratio. However circular path welding have lower tensile strength
compared to linear path welding due to the difficulties faced when welding in a circular
motion.
The research and development team at HITACHI has developed a device for Friction
Stir Welding of 25m aluminum material . The team found that through FSW they are able
to weld the aluminum double material used for train tracks, without the fear of strength
reduction and also emission of gas. The welded joint is clean, safe and also have a smooth

surface finish. The team also tested and compared FSW with Metal Inert Gas
welding(MIG), and they found that FSW has higher tensile strength compared to MIG.
Through Charpy Impact test, it was found that the impact strength of the joints welded by
Friction Stir Welding is 1.7 times greater than that of the parent metal, and 2.4 times
stronger than that of joints welded by MIG..

CONCLUSION

In view of these journals, Friction Stir Welding can be said to be a gainful procedure
for automobile manufacturing furthermore progression in space exploration. This is on
the grounds that aluminum-magnesium alloy has been utilized as a part of manufacturing
autos, for example, Land Rovers[11] while the aluminum-lithium alloy has been utilized
as a part of manufacturing space crafts. Friction Stir Welding ought to be just utilized
under the correct conditions, for example, the best possible feed rate to rotational speed
ratio furthermore the proper apparatus geometry to deliver a good quality weld..

REFERENCE

"Friction-stir Welding : A researcher talks about some recent technical issues :

Research & Development : Hitachi", Hitachi.com, 2016. [Online]. Available:
http://www.hitachi.com/rd/portal/contents/story/monozukuri_platform/index.htm1

H.-S. Lee and K. No, "Friction stir welding process of aluminum-lithium alloy
2195,"

Procedia Engineering, vol. 149, pp. 6266, 2016.

H. K. Sharma and K. Shah, "Experimental analysis of friction stir welding of

dissimilar alloys AA6061 and mg AZ31 using circular butt joint geometry,"
Procedia Technology, vol. 23, pp. 566572, 2016.

"FSW : Hitachi-Rail.com", Hitachi-rail.com, 2016. [Online]. Available:

http://www.hitachi-rail.com/products/rolling_stock/a_train/feature02.html.