FRICTION

STIR
WELDING
 WELDING PROCESS

• Welding is a process of joining of different or similar material.

• Advantages
• economical
• considerable freedom in designing
• large no. of dissimilar or similar materials joined
• weld as strong as the parent metal
 DIFFERENT TYPES OF WELDING PROCESSES

1. Arc Welding.

2. Oxy Fuel Gas Welding.

3. Resistance Welding

4. Solid State Welding

 1. ARC WELDING
 Carbon Arc Welding
 Electro Gas Welding
 Gas Metal Arc Welding
 Gas Tungsten Arc Welding
 Plasma Arc Welding
 Shielded Metal Arc Welding
 Submerged Arc Welding
 2.OXYFUEL GAS WELDING

 Air Acetylene Welding

 Oxy Acetylene Welding
 Oxy Hydrogen Welding
 Pressure Gas Welding
 3. RESISTANCE WELDING

 Projection Welding

 Resistance Seam Welding

 Resistance Spot Welding

 4. SOLID STATE WELDING

 Cold Welding
 Diffusion Welding
 Explosion Welding
 Roll Welding
 Hot Pressure Welding
 Friction Welding
 Friction Stir Welding
GROWTH OF WELDING PROCESSES AFTER THE INVENTION
OF ELECTRIC ARC
• Future developments in
welding processes are
expected through
fundamental understanding
of physical processes
 FRICTION STIR WELDING PROCESS
• Friction stir welding is a new solid state joining process.

• Here a cylindrical shouldered tool along with a profiled probe is rotated and fed at
a constant traverse rate in to the joint.

• Frictional heat generated between the wear resistant welding tool and the workpiece
along with mechanical mixing heat causes the stirred material to soften without
reaching the melting point and allows the traversing of the tool along the weld line.

• The plasticized material is transferred from the leading edge of the tool to its trailing
edge and is forged by the intimate contact of the tool shoulder and the pin profile
thus leaving a solid bond between two phases.
 SCHEMATIC DIAGRAM OF THE FSW PROCESS

Two discrete metal workpieces butted together, The progress of the tool through the joint,
along with the tool (with a probe). also showing the weld zone and the region
affected by the tool shoulder.
MICROSTRUCTURE CLASSIFICATION OF FRICTION STIR
WELDING

A. Unaffected material
B. Heat affected zone (HAZ)
C. Thermo-mechanically affected zone (TMAZ)
D. Weld nugget (Part of thermo-mechanically affected zone)
 TOOLS USED FOR FRICTION STIR WELDING

• High speed steel is used for welding aluminium

• For welding steel and tungsten alloys tungsten and iridium alloy based tool is used.

Tool pin holder ORNL W-based alloy ORNL Ir-based alloy

FRICTION STIR WELDING OF TI AND STEEL ALLOYS

Ti-6-4, t=¼”

SS304, t=¼”
 MATERIALS AND THICKNESS

Friction stir welding can be used for joining

•2000, 5000,6000,7000 series aluminum.
•Aluminium based metal matrix composites
•Copper and its alloys (up to 50mm in one pass).
•Lead.
•Titanium and its alloys.
•Zinc, plastic, stainless steel and nickel alloys.
 PROCESS ADVANTAGES
• Low distortion, even in long welds.
• Excellent mechanical properties as proven by fatigue, tensile and bend tests.
• No arc, fume, spatter and porosity
• Low shrinkage.
• Can operate in all positions.
• Non consumable tool.
• No filler wire, gas shielding.
• Can weld aluminum and copper of >50mm thickness on one pass
 FSW IDEALLY SUITED FOR AL- SIC
COMPOSITES
FSW

Laser

Laser welding destroys the

microstructure.
In contrast, the base metal
microstructure is retained in the weld
zone after friction stir welding.
 FRICTION STIR SPOT WELDING.

• FSSW has generated tremendous interests in the automotive industry

•Direct replacement of resistance spot welding of AL
•Significant energy and cost savings
•Potential for advanced high-strength steels and other high-temperature
alloys
• Opportunities in other industries
MAZDA RX-8 REAR DOOR (ALUMINUM PANEL) IS MADE
BY FSSW

• Robotic FSSW system replaces

resistance spot welding system
ADVANTAGES OF CHANGING FROM RESISTANCE SPOT WELDING
TO FSSW
Welding
air
Power
supply water
Robot
Controller Welding
controller
Welding
trans.

Welding Welding junctio

Gun cable n box
Electrode
dresser

Robot Cables
 FRICTION STIR SPOT WELDING SYSTEM

Eliminated water,
air, and welding
power supplies. Robot
controller
99% energy
saving (vs. RSW,
according to
Mazda)
Welding
40% investment Gun

reduction (vs.
RSW)
Robot Cables
 APPLICATIONS OF FRICTION STIR WELDING

1. Ship building and marine industries

• Panels for decks, bulk heads and floors
• Hulls and superstructures
• Helicopter landing platforms
• Mast and booms (sailing boat)
 APPLICATIONS OF FRICTION STIR WELDING (CONTD.)

2. Aerospace industry
• Cryogenic fuel tank for space
vehicles
• Aviation fuel tanks
• Military and scientific rockets
• Various primary and secondary
structural component
 APPLICATIONS OF FRICTION STIR WELDING (CONTD.)

3. Railway and land transport.

• High speed trains
• Railway tankers and goods wagon
• Wheel rims
• Motor cycle and bicycle frames
 FUTURE DEVELOPMENTS

• Friction stir welding for piping system

• Integrating FSW with other processes (hybrid processes)

 LIMITATIONS OF FRICTION STIR WELDING

• Workpieces must be rigidly clamped

• Backing bar required (except for self reacting and directly opposed tools)
• Key holes at the end of each weld
• Cannot make joints that require metal deposition
• Less flexible than manual and arc processes
 CONCLUSION

New technology with vital application in aerospace an marine

Presently limited to aluminum ,its alloys and related metals
FSW of steel and titanium alloys are developed and they are in
the nascent stage
Will emerge as a better welding technology
 BIBLIOGRAPHY

• FRICTION STIR WELDING, KEVIN J. COLLIGAN

• FRICTION STIR WELDING OF ADVANCED MATERIAL
• WWW.WIKIPEDIA.ORG
• WWW.TWI.UK