FRICTION STIR

WELDING

PRESENTED BY : SHASHANK
VERMA
1702940142
WELDING & TYPES OF WELDING

 Welding is a joining process.

 Application of heat.
 With / without application of pressure & electrode.
 Making permanent joints.
 two types:
 FUSION WELDING : heated to molten state.
 no pressure is required.
 eg. Gas welding , arc welding
 PLASTIC WELDING : heated to plastic state.
 pressure is required.
 eg. friction welding , forged welding
INTRODUCTION

 FSW was invented by Wayne Thomas at TWI (the welding institute) ltd in 1991.
 It overcome many of the problem associated with conventional joining techniques.
 FSW is low energy input, capable of producing very high strength weld in wide
range of materials at low cost.
 FSW process take place in the solid phase below the melting point of the material
to be joined.
 FSW is solid state welding process.
 Weld created by Mean of friction heating and mechanical deformation.
 Unlike fusion welding here no filler material is used.
 Commonly used for aluminium and its alloy.
 THEORY OF FSW

 FSW transform the metal from a solid state into a plastic

state.
 The tool mechanically stirs the material together under
pressure to form a welding joint.
 FSW uses rotating, non consumable tool moved along the
length of joint.
 The rotation of heat up and plasticizes the material contact
with tool.
 Forging force is applied to the weld region by the tool.
WORKING PRINCIPLE OF FSW :
WORKING PRINCIPLE OF FSW

 FSW a cylindrical , shouldered tool with a profiled probe /pin is rotated and
slowly plunged into the joint line between two piece butted together.

 Fractional heat generated between the wear resistance welding tool and
material of the work pieces.

 The heat is without reaching the melting point and allow traversing of the
tool along the weld line.

 The plasticized material transferred the front edge of the tool to back edge
of the tool probe, it is forged by the intimate contact of the tool shoulder
and pin profile.
STEPS OF FSW PROCESS

 1. PLUNGE STAGE

 2. DWELL STAGE

 3. WELDING STAGE

 4. PULL OUT STAGE

 MICROSTRUCTURE FEATURES

Four different regions namely-

1. UNAFFECTED MATERIAL

2. HEAT AFFECTED ZONE (HAZ)

3. THERMO- MECHANICALLY AFFECTED ZONE

4. WELD NUGGET (WN) OR STIRRED ZONE

 MICROSTRUCTURE ANALYSIS OF
FSW

 UNAFFECTED MATERIAL

 This material remote from the weld, which has not be deformed.
 No microstructural change occur in this zone.

 HEAT AFFECTED ZONE (HAZ)

 A very little microstructure change occur in the HAZ due to the heat of welding.
 No plastic deformation occurring in this area.
 The microstructure in this zone consist of coarse grained structure.
MICROSTRUCTURE ANALYSIS OF FSW

 THERMO-MECHANICALLY AFFECTED ZONE (TMAZ)

 In this region adjacent to weld zone.

 TMAZ undergoes plastic deformation but no crystallization occurs.
 The grain are elongated in nature.

 STIR ZONE

 The weld region that has direct interaction with tool probe.
 Extreme strain and elevated temperature cause recrystallization of material.
 This region consist of very fine equi axed grains.
 TOOLS PARAMETERS

 Commonly used tool materials -

 High speed steel .
 EN Steel
 PCBN

 Tool is strong , tough , hard wearing at welding

temperature.

 Have good oxidation resistance , thermal conductivity

COMMON TOOLS
SOME OF THE FSW MACHINE
JOINT GEOMETRY

 It can be used in all positions-

 Horizontal
 Vertical
 Overhead
 Orbit
 ADVANTAGES

 Goodmechanical properties fatigue ,tensile and

bend test.
 No arc and no porosity.
 Can operate in all position.
 Energy efficient.
 Environmentally clean process.
 Weld a wide range of alloy.
 DISADVANTAGES

 Work pieces must be rigidly clamped.

 Keyhole at the end of each weld.
 Can not make a joint which required metal
deposition.
 Initial
cost of machine is very high compare by fusion
welding.
APPLICATIONS

 AEROSPACE APPLICATION.

 SHIP BUILDING AND AUTOMAOTIVE WORKS.

 STRUCTURAL FABRICATION WORKS.

 RAILWAYS AND LAND TRANSPORT.

 MAIN FSW MACHINE IN INDIA

 HAL , AEROSPACE DIVISION , BANGALORE.

 BHEL, THIRUCHIRAPALLY.

 INDIAN INSTITUTE OF SCIENCE, (IISC BANGALORE)

 CONCLUSION

 FSW opening up new area of welding daily.

 No distortion, spatter, fumes.
 Welding at below melting point of work pieces.
 Good forging action by tool.
 It is alternative to fusion welding.
 Safe and eco friendly operation in FSW.
 FSW can used for wide variety of application.
THANK YOU!