Friction Stir Welding

Guided by: Prof. S. K. Kadu

Presented By :
1)Pethkar Saurav Ramkrishna
Contents
Introduction
Need of Project
Literature Review
Problem Definition
Principal
Methodology
Engine Specification
Performance &Emission analysis
Construction & Working
Project Outcomes
References
Introduction

Process invented in 1991 by Wayne Thomas , TWI

Utilizes a rotating, non-consuming tool, consisting of a
‘Pin’ and a ‘Shoulder’
At each instance, the joint is formed in a solid state
 Principal
• Rotating pin is pushed into the material until shoulder
meets the workpiece surface after a while this causes the
material to plasticize due to heating by frictional contact
of the tool shoulder and the workpiece
• Tool is moved forward, and the joint is formed behind
the tool
• Process is finished when the tool is retracted from the
workpiece workpiece
Benefits of FWS

NO hot cracks , no gas pores

NO shielidinh gases or consumables
Possibility of joining dissimilar alloy/materials No
fusion Low heat-Input
Welding possible in all positions
Limited weld seam prepartions (degresing)
Few softening or Deformation
 Constant weld quality achieved together with high productivity
 Safey;
- no UV-radiation
- no welding fume
- no spattering
 6xxx series Al alloys: possibility to weld 1.2 mm upto > 65 mm
( upper limiy determined by maximum power )
 Fully maintence
 Flat welding surface without reinforcement
Drawsbacks of FSW

Large forces : order of magnitude 10 KN (backing plate

required)
Rigid clamping system needed
‘Hole’ at the end of the weld
 Problems if weld gap > 10% material thickness
Investment cost (equipment with high stiffness)
 Other weld flaws are possible
Equipment
Current FSW applications: aluminium
Current applications:copper
Further application?

 Friction Stir Welding of:

- Zn for roofing (welding speeds up to 1.8 m/min at thickness of 0.8mm)
- Mg alloys
- Thermoplastics
- Titanium
, steel and stainless steel ( still challenging with repect to the material due to the higher
temperature and forces
Literature Review
Paper No. Name of Paper Author Name Conclusion

1 Efficient Combustion Dezhi Zhou, Increasing efficiency of

Modelling Wenming Yang four stroke petrol engine

2 Hydrogen Powered Dr. Aditya Varma Renewable hydrogen

Petrol Engine based fuel utilization.

3 Emission analysis of P.R.Chitragar Due to ecological

SI Engine reasons hydrogen and
LPG may be suggested
as an alternative fuel for
SI engine.