Mr.

IAK REddy

Associate Professor
Department of Mechanical
Engineering
NIT- Warangal.

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 Methodology
Selection of Material

Optimization of FSW Process Parameters Using Taguchi

Method

Optimization of Tool transition geometry Using Taguchi

Method

Multi Pass FSW Radiography Post Weld Heat

Treatment

Characterization of
Weldments

Metallography Mechanical Properties

Tensile Impact toughness Microhardness

SEM & Optical Microscopy

Fractogrphy

ANALYSIS OF DATA
 History
• Wayne Thomas invented Friction Stir Welding in
1991 at The Welding Institute (TWI) in UK .

Friction Stir Welding

• A solid-state joining process.
• Heat is generated between the tool and material which
leads to a very soft region near the FSW tool.

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 Comparison with other joining processes
FSW vs Fusion Welding FSW vs Riveting

» Improved Mechanical » Reduced Part Count

Properties » Reduced Production Time
» Reduced Distortion » Reduced Defect Rates
» Reduced Defect Rate » Increase in Load Carrying
» Simplifies Dissimilar Capability
Alloy Welding » Improved Fracture
» Eliminates Consumables Performance
» Reduces Health Hazard » Eliminates Consumables
» Less Operator Dependent
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Applications

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 Material Suitability To Fabricate

• Al and its alloys • Similar metals joints

• Copper and its alloys • Dissimilar metals joints
• Lead • Surface Composites
• Titanium and its
alloys • Surface Metal Matrix
• Magnesium alloys Composites
• Zinc • Hybrid composites
• Plastics • Nano composite
• Mild steel • Hybrid nano composite
• Stainless steel
• Nickel alloys • To produce Ultra Fine
Grained structures 6
Friction Stir Welding

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Tools Parameters

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 Friction Stir Processing (FSP)
• Friction Stir Processing (FSP) is a novel surface
modifying technique that provides microstructural
modification and control in the near-surface layer of
metal components.

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 Disadvantages
▪ Exit hole left when tool is withdrawn and special
tooling.
▪ Large down forces required with heavy duty
clamping necessary to hold the plates together.

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 THANK YOU

Dr. A. Kumar, Associate Professor,

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Mechanical Engineering Department