Friction stir welding is a solid-state joining process that uses a rotating tool to plunge between and stir together two clamped metal plates without melting them. This results in a high quality weld without defects from traditional fusion welding. The tool design, including the shoulder shape and material, and process parameters like rotation speed and downward force affect the heat generation and material flow during welding. Tungsten is often used as the tool material due to its high melting point, heat resistance, and dimensional stability at high temperatures.
Friction stir welding is a solid-state joining process that uses a rotating tool to plunge between and stir together two clamped metal plates without melting them. This results in a high quality weld without defects from traditional fusion welding. The tool design, including the shoulder shape and material, and process parameters like rotation speed and downward force affect the heat generation and material flow during welding. Tungsten is often used as the tool material due to its high melting point, heat resistance, and dimensional stability at high temperatures.
Friction stir welding is a solid-state joining process that uses a rotating tool to plunge between and stir together two clamped metal plates without melting them. This results in a high quality weld without defects from traditional fusion welding. The tool design, including the shoulder shape and material, and process parameters like rotation speed and downward force affect the heat generation and material flow during welding. Tungsten is often used as the tool material due to its high melting point, heat resistance, and dimensional stability at high temperatures.
• It is a solid-state joining process (the metal is not melted).
• Friction Stir Welding transforms the metals from a solid state into a plastic state, and then mechanically stirs the materials together under pressure to form a welded joint • In the process a rotating FSW tool is plunged between two clamped plates. The frictional heat causes a plasticised zone to form around the tool. The rotating tool moves along the joint line. A consolidated solid- phase joint is formed. • No filler metal is required. Advantage over arc welding
• High quality weld can be achieved.
with absence of solidification cracking
porosity oxidation Other defect resulting from traditional fusion welding
• lower apparent energy input of FSW
less distortion and residual stress Tool geometry • Optimum tool design will produce the desired joint quality as well as enable higher welding speed and longer life.
• The shape of the bottom of the tool shoulder effects material
flow around the tool nib.
can be flat or concacve
smooth or grooved with concentric or spiral grooves • A concave shoulder has the advantage compared with the flat bottom directing material flow to the center close the tool nib. Tool shoulder material and backing material
• Tool shoulder play an important role in the heat generation
process of FS welding.
• Compared to tool steel the shoulder made from zirconia engg
ceramics seems to generate approx 30 to 70% more heat depending on the welding parameters.
• The welding efficency is affected by the heat loss through
tool. • Heat generation depend on the two parameters i.e force and rpm Tool shoulder material
Using a tool material having low thermal conductivity
heat loss can be substantially reduced This will enable increasing welding speed As increase in welding speed a similar increase in rotational speed to get the good welding. Heat generation • Heat generation is a FSW process increase with increasing tool rotation speed and tool downward force. • Travel speed influences rate of heat input Affecting metal flow around the tool nib. • Other parameters are shoulder radius shoulder angle of the FSW tool • Time of indentation i.e the period between the instant tool contact the work piece and the instant the tool begin moving along the joint. • can range usually from 5 to 30s. Microstructure zone found in FSW
Region Material flow Temperature
Weld nugget high high
Thermo – mechanically low medium
affected zone TMAZ Heat affected zone none medium Why we use tungsten? • Friction stir welding (FSW) of hard metals such as steel and titanium requires unique tool materials capable of achieving long linear lengths while minimizing tool degradation. Tungsten-based materials have demonstrated success as a FSW tool material in resisting degradation while maximizing tool life.
Tool material properties:
• Tungsten are very efficient as a tool, because other metal doesn’t have such good heat resistance. • Highest melting point among all the metal • Suitable for very high temperature application. • Low coefficient of thermal expansion • High level of dimensional stability