IEEE-International Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012 305

Design and Development of Low Cost Friction Stir Welding Machine

S. Arularasu* and A. lothilingam**

* PG Student, Department of Production Technology, MIT Campus, Anna University, Ch - 44.

E-mail-arularasu_72@yahoo.com
** Professor and head, Department of Production Technology, MIT Campus, Anna University, Ch - 44

Abstract
Aluminum of Norway. In 2008, an industry-changing
In major industries, most of the parts are event occurred when Manufacturing Technology, Inc.
manufacturing in aluminum material by welding merged with Transformation Technologies, Inc.
process and the part must have two major factors, (TTl) under the MTI banner. The coming together of
such as surface finish and the welding quality. these two powerhouse companies combined the
Conventional welding process is not preferred spectacular innovation of Friction Stir Welding
because temper characteristic of material will be (FSW) with MTI's long-established expertise and
changed. To overcome this drawback friction stir global leadership in friction welding solutions.
welding is processed. Friction stir welding machine MTI is the only company in the world
manufacturers are developing machines of costs whose core business is the development, design and
above Rs. I 5. 00, 000/-. Its cost is considerably high building of all forms of friction welding machines
for the buyers who were under research scholars, and systems, including Friction Stir Welding. They
educational institutions and small scale industries. are licensed and listed by The Welding
Hence by this research we can provide a best and Institute (TWI-England) as a Friction Stir Welding
suitable machine for their purpose at very low cost (FSW) machine manufacturer.
without change in its robustness while compared to MTI Friction Stir Welding machines, like
other friction stir welding machines. Due to the LS-1 and GG-1 are used for research and
compactness and low cost of this machine, it is very development purposes by The Welding
suitable for small industries, researchers and Institute, Brigham Young University, Idaho National
educational institutions. The low cost is achieved by Laboratory, Mitsubishi Heavy Industries, and Spirit
its compactness and simple mechanism. Aero systems. MTI Friction Stir Welding machines
are also used in production applications for
electronics cooling in the automotive industry, fuel
1. Introduction tanks, sputtering discs, axle assemblies, half-shafts,
conductor rails, coil joining, deck plate joining, and
The cost of friction stir welding machine is other production items in various markets.
too high, due to its full automation and its The ESAB super stir ™ range is purpose­
specifications. The space required for the friction stir built for high- volume production of large aluminum
welding machine is large. To overcome these panels, grinders and truses
problems this research will give a compact friction
stir welding machine at low cost. 3. Aim
By using this friction stir welding machine To construct friction stir welding machine at
the aluminum material can be weld without any low cost
change in its properties at the same time the welded
portion will have high degree of surface finish and
3.1 Objective
high quality welding. Hence hardened material is
used as a tool it can weld over a wide range of plates. Construction of compact friction stir welding
machine (manually operated) at low cost for joining
2. Literature research aluminum plates. It is achieved by its compactness
and simple mechanism. It can be automatically
In 1996, ESAB's first friction stir welding operated by PLC control with servo motor.
machine, Super Stir™, is supplied to Marine Aluminum welding could be done without change in

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 IEEE-International Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012 306

its temper characteristics because the weld has been 5. Methodology

done before the metal reaches its recrystalization
temperature. This machine will give high degree of

I
surface fmish and high quality of welding. There is
no need of secondary process like heat treatment and
grinding.

3.2 Scope

Due to portability of this machine, we can

shift it to the required work place. Aluminum stir
welding can be done at low cost in small work pieces.
Aluminum welding could not be done by
conventional process because its temper
characteristic will be changed. To overcome this
drawback this friction stir welding machine is
suitable.

4. Working principle of friction stir

welding

In friction stir welding a cylindrical

shouldered tool, with a profiled threaded/unthreaded
probe (non- consumable) is rotated at a constant
speed and fed at a constant traverse rate into the joint
line between two pieces of plate material, which are
butted together. Frictional heat is generated between
the wear-resistant welding tool shoulder and nib and
the material of the work pieces. This causes the
stirred materials to soften without reaching the
recrystalization temperature. Allowing the traversing
of the tool along the weld line plasticized material to
the back of the pin while applying a substantial
forging force to consolidate the weld metal.
PIbriadionIDd......,ty oflDlClbineia to
bodoDO.
Vertical force to maintain
sufficient frictional contact

� JOint
Line

Tool
Shoulder

cDtyupE 1. O1loO)(J npoypoocr ocj> OEAO

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6. Machine model in alcohol, though it can be soluble in water in certain

forms. The yield strength of pure aluminum is 7-
11 Mpa, while aluminum alloys have yield strengths
ranging from 200 MPa to 600 MPa. Aluminum has
about one-third the density and stiffness of steel It is
widely used aluminum alloy

Ta/3A£ 1. X0l-11tomnov Ocj> AAUlllVUIl (2024)

Alloy Si Fe Cu Mn Mg Zn Ti

2024 1 1 3.8- 0.3 1- 1.2- 0.3 0.2

4.9 0.9 1.8

7.2. Tool material

7.2.1. High speed steel

High speed steel (HSS or HS) is a subset

of tool steels, usually used in tool bits and cutting. It
is often used in power saw blades and drill bits. It is
superior to the older high carbon tools used
extensively through the 1940s in that it can withstand
higher temperatures without losing its temper
(hardness). This property allows HSS to faster than
high carbon steel, hence the name high speed steel.
At room temperature, in their generally
Main parts of the machine; recommended heat treatment, HSS grades generally
1. Spindle head display high hardness (aboveHRC60) and a high
2. Column abrasion resistance (generally linked
3. Base to tungsten content often used in HSS) compared to
4. Motor common carbon and tool steel
5. Cross rail handle
6. Saddle handle
7.2.2. HSS M2
7. Driving pulley
8. driven pulley
Tool material must withstand the
9. vertical displacement handle temperature developed during welding and must have
good wear resistance and strength for long life.
7. Selection of material Hence HSS M2 material is selected and hardened up
t060HRC.
M2 is a high speed steel in tungsten­
7.1Work piece material
molybdenum series. The carbides in it are small and
evenly distributed. It has high wear resistance. After
7.1.1 Aluminum (2024) heat treatment, its hardness is the same as Tl, but its
bending strength can reach 4700 MPa, and its
Aluminum is remarkable for the metal's low density toughness and thermo plasticity are higher than Tl by
and for its ability to resist corrosion due to the 50%. It is usually used to manufacture a variety of
phenomenon of passivation. Structural components tools, such as drill bits, taps and reamers. Its
made from aluminum and its alloys are vital to decarburization sensitivity is a little bit high.
the aerospace industry and are very important in BS4659BM2 is a general purpose high speed steel.
other areas of transportation and building. Aluminum M2 high speed steel offers good wear resistance with
is a soft, durable, lightweight, ductile and malleable excellent toughness and cutting power.
material with appearance ranging from silvery to dull
gray, depending on the surface roughness. Aluminum
is nonmagnetic and non-sparking. It is also insoluble

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 IEEE-International Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012 308

Grade
C Cr Mo W V

M2 0. 95 4.2 5 6 2

7.2.3. Hardening
0
The tool is uniformly heated up to 801990 C
AI. 50x100x5mm - 2nos
then quenched in oil.

7.3 Fixture material

EN 24 can be further surface-hardened to

create components with enhanced wear resistance by
induction or nitrating processing EN24 has a tensile
2
strength of up to 850/1000 N/mm • Fixture material
must withstand the temperature developed during
welding and must have wear resistance for long life.
Hence EN-24 material is selected and hardened up to
55HRC.

Ta�A.E 3. X0J.l1to<Jlnov 0<1> EN 24

C Si Mn Ni Cr Mo

0.40% 0.3 0% 0.60% 1.50% 1.20% 0.25% all dimensions are in mm

WtYUPE 4. napaJ.lE'tEpa 0<1> <l>tS-ruPE
7.3.1. Hardening
10. Design of spindle
The fixture is uniformly heated up to
0
823/850 C then quenched in oil. The spindle of the machine must have the
capability of holding any dimensions of tool. Tool is
7.3.2 Stress relieving to be hold in the collet of the adapter, the standard
size of the adapter will be fitted to the spindle, hence
°
The fixture is heated slowly 650 to 670 C the bore of the spindle must be according to the size
and soaked well before cooling in a furnace or in air. of the adapter to hold robust. Hence standard size of
IS040 adapter is selected. The bore of the spindle
8. Important welding parameters must have the standard taper ratio required by the
ISO 40 adapter. Another side of the spindle fitted in
Tool rotation and traverse speed the driving unit. i.e., the spindle is externally splined
Tool tilt and plunge depth to transmit the both rotational and linear movement.
Tool design The rotational movement is given to the spindle by
Welding forces means of internally splined pulley (driven), the
Flow of material driven pulley is connected to the driver pulley by
Generation and flow of heat means of belt drive. Various speeds can be achieved
by means of using stepped cone pulley. Either the
speed can be controlled by means of PLC system
9. Design of fixture
with servo motor. Hence EN 8 material is preferred.

According to the parameter of the work

piece, fixture had been designed.

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 IEEE-International Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012 309

3. Research purpose,
4. Joining small size work pieces, etc,.

13. Advantages

Due to portability of this machine, we can

,-if,:))1 shift it to the required work place.
'Ti: po" is)''I) Aluminum stir welding can be done at low
�(tJ?' (tS J d "'2rsi:!'s
cost in small work pieces.
:n: " rr
Good mechanical properties in the welding
process.
Improved safety due to the absence of toxic
fumes or the spatter of molten material
11. Design of tool No need of skilled operator
Low environmental pollution
Dimensions of tool (unthreaded / threaded probe) No conswnables.

Probe Dia = Thickness Of W/P(5mm)x1.2

14. Disadvantages
=6mm

Same thickness plates can only joined.

Probe Length = Thickness Of WIP - 0.02
Tool profile will be made at the [mal
=4.9Smm
welding portion.
(thickness reduced due to compression)
Non linear welds cannot be done
(The length of the nib is slightly less than the weld
depth required and the tool shoulder should be in
15. Approximate cost estimation
intimate contact with the work surface. The nib is
then moved against the work, or vice versa. For 5mm
thickness , we may apply 1-5 ton forging load. The Sl.

weld quality may vary depends upon the load. Here, No. Parts Quantity Cost(Rs.)
we will take 2 ton load) Three phase
1 motor (2-hp) Ino 4000
Shoulder Dia = 3 X Probe Dia
Machine
=ISmm
2 components
A. Base Ino 2000
tool tilt = 2-4 degree
B. Column Ino 3 000
C. Head Ino 2000

D. Drive unit Ino 2500

3 Main spindle Ino 2000
Cross rail with
4 saddle Ino 3 500

'-------.'::...�.Jy.x:-------' -".,:,1)0 ':p'k_-;' 5 Tool Ino 1500

':::;hcu.d:r �
..-l. ·:·i�It;·n::i·_·t·:::.
in � Il
L"r',:,
6 Fixture Ino 3 000
Aluminum plate
7 W/P 1m 1000

Fabrication,

12. Application assembly and

other finishing
Due to compactness and low cost it is most S works - 2500
applicable for, TOTAL 27000 /-
1. Educational institutions,
2. Small scale industries,

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 IEEE-International Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012 310

16. Conclusion [9] Elangovan K, Balasubramanian V and Valliappan M

(2008), Influences of tool pin Profile and axial force on the
formation of friction stir welding processing zone in
By using this machine, friction stir welding AA6061 aluminium alloy, International journal of
process in the aluminum material can be weld advanced manufacturing technology, Volume 38, pp 285-
without any change in its properties at the same time 295.
the welded portion will have high degree of surface
finish and high quality welding. Hence hardened [10] Juvinal R C and Marshek K M. (2006) Fundamentals

material is used as a tool it can weld over a wide of Machine component design, Fourth edition, Jon Wiley
and Sons, Asia
range of plates. The only drawback is at final welding
portion the tool profile will be made. Depends upon
[11] Kutz M. (1999) Mechanical engineers handbook,
the various parameters such as tool design, w/p
second edition, Myer Kutz Associates, Inc, Couldada.
material, forging load, the weld quality may be
changed. This machine is very much suitable for [12] Shigley J E, Mischke C R and Budynas R G. (2004)
small scale industries, educational institutions, for Mechanical Engineering Design, Seventh Edition, mcgraw
researchers, etc., due to its compactness and its low Hill.
cost.
[13] Ulysee P. (2002) Three-dimensional modelling of the
friction stir-welding process, International journal of
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15557.
[1] W.J. Arbegast, "Friction stir welding: After a decade of
development", Welding Journal, March 2006, pp.28-35.
[14] w.m. thomas, e.d. nicholas, j.c. needham, m.g murch,

[2] V. Soundararajan, M. Valant and R. Kovacevic,

[15] P. Templesmith, and c.j. dawes, friction stir butt
"Joining of Aluminum Alloy to Steel using Friction Stir
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Manufacture, April 2006.
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[3] C. Chen, and R. Kovacevic, "Joining of Al 6061 alloy

[16] T. Minton, DJ. Mynors, Utilisation of engineering
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[17] t. Watanabe, h. Takayama, a. Yanagisawa, joining of

[4] Khazanov 1.0., Fomin N.I., (Tomsk Polytechnical
aluminum alloy to steel by friction stir welding, journal of
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materials processing technology 178 (2006) 342-349.
superplasticity of High-Speed Tool Steel" Welding
International 1990 4 8 633-634 (Selected from Svarochnoe
[18] An overview of r&d work in friction Stir welding at
1989 36 4-5, Reference SP/89/3/4, Translation 860)
smu v. Soundararajan, m. Valant and r. Kovacevic*
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[5] Benson P.G., Backlund J., 'Possibilities with aluminium
department of mechanical engineering southern methodist
extrusions joined by friction Stir welding'. 4th Int Forum on
university, dallas, texas
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[6] design, development and analysis of theFriction stir

[19] Technical hand book (friction stir welding)
welding process-calvin blignault
ESAB AB Welding Automation ltd

[7] Technical hand book (friction stir welding) ETA

[20] fundamentals of modem manufacturing-
technology PVT. ltd
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[8] Conceptual design of a friction stir welding machine for

joining rails Fulufhelo masithulela

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