Friction Welding

Friction Welding

FRW-1 FRW-2 FRW-3 FRW-4 FRW-5

Steps Involved in Friction welding process
Characteristics of typical continuous drive friction welding
Friction weldability of similar and
dissimilar metals
Effect of varying pressure on interface
temperature
Radial temperature distribution from interface in friction
welding of low carbon steel
Visual view of friction welded
Ti-Al
Visual view of friction welded
Fe-Al
 Cut section of Fe-Al friction welds
a) 6-9-3; b)6-9-5; c)6-18-3; d) 6-18-5
 Friction welding of AISI 304 & AISI 4140

Chemical composition of AISI 304 and AISI 4140

Parent C Cr Mn Ni Si Mo Fe
Metal
AISI 304 0.06 18.4 1.38 8.17 0.32 ---- Balance

AISI 4140 0.40 1.1 0.75 ---- 0.31 0.28 Balance

 Welding parameters

Trial Welded Joint Bum-off, Friction Force, Upset Force, Rotational

(mm) (KN) (KN) Speed,
(RPM)

1
304-4140 5 37.5 50 1500

2
304-4140 7 37.5 50 1500
3
304-4140 9 37.5 50 1500
4
304-4140 12 37.5 50 1500
Friction welded AISI 304 & AISI 4140
Macrographs for longitudinal cut sections for the welds
Micro structure of dissimilar weldment at
center and periphery
Detailed Mictrostructure
 B5

B12

Elemental distribution
across the weld zone
X-Ray diffraction patterns for friction weldment as
welded condition burn-off length B5 and B7
Line mapping of the sample (AISI 340-AISI 4140)
having burn-off length 5 and 12 mm respectively in as
weld-condition.
 400
320
304 4140
304 4140 side side
270 side side 300

Hardness HV
Hardness HV

220
B-5 B-7
200
170

120 100
-6 -4 -2 0 2 4 6 -6 -4 -2 0 2 4 6
Distance along the weld center (mm) Distance along the weld center

400 500
304 4140
side side
400
300 304 4140
Hardness HV

Hardness HV

side side
300
B-9 B-12
200
200

100 100
-6 -4 -2 0 2 4 6 -6 -4 -2 0 2 4 6
Distance along the weld centre (mm) Distance along the weld centre

Micro Hardness across the weld zone by varying

the burn off length
 FRW

B5 B7 B9 B12
AISI 304

Weld

AISI 4140

Burn off Yield Stress Ext.Yield

length (MPa) (%)
B-5 487.2 18.15
B-7 496.5 18.89
B-9 472.7 15.20
B-12 474.8 18.30
Tensile Fractographs of friction welded AISI 304 and
AISI 4140 by keeping burn off length 5 mm
SEM/EDAX graph shows the friction weldment made by
keeping 9 mm burn off length, exposed at 600 ºC under
K2SO4 (40%) and NaCl (60 %) after 50 cycles
Plots of cumulative weight gain (mg/cm2) as a function
of time (number of cycles) for the friction weldment in
the molten salt environment.
BSEI and X-ray mappings of the cross-section of dissimilar
friction welded 304 and 4140 by keeping burn-off length
7mm exposed to K2SO4+NaCl(60%)at 600 ºC for 50 cycles.
Friction Stir Welding (FSW)
 Friction Stir Welding :
Friction at work

“Friction-stir welding (FSW) is a solid-state joining process (the

metal is not melted) and is used when the original metal
characteristics must remain unchanged as much as possible.”

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 Friction Stir Welding (FSW)
FSW process in which a rotating tool is fed along a joint line
between two work pieces, generating friction heat and
mechanically stirring the metal to form the weld seam
• Distinguished from FRW because heat is generated by a
separate wear-resistant tool rather than the parts
• Friction stir welding is a breakthrough joining process
with about nearly 20 years maturity,

(1) Rotating tool just before entering work,

FSW-1 FSW-2 FSW-3 (2) partially completed weld seam
 Submerged Friction Stir Welding
• The case when the joining process is run underwater
• Has been shown to be useful to prevent overheating
• May produce lower grain sizes
• Article from physics.com (May 16, 2007):
– “New process generates hydrogen from aluminum alloy to
run engines, fuel cells”
• The reaction continues therefore until all aluminum is used
• “Hydrogen gas generation in the wet cutting of aluminum and
its alloys”, shows that when aluminum is cut underwater there
is a fresh surface revealed which reacts with the water and
hydrogen is released.
• probable chemical reaction:
– 2Al + 3H2O → Al2O3 + 3H2
 FSW in Aeronatical

New joining processes associated with new materials can improve the
aeronautical structures, reducing their environmental impact and improving their
efficiency.
FSW can replace older joining processes in these structures, mainly riveting,
creating leaner joints at lower costs.

Friction Stir Welding is the most recent upgrade to the

Space Shuttle’s gigantic External Tank, the largest
element of the Space Shuttle and the only element not
reusable.

1993, NASA -Al 2219–used on the original Space

Shuttle External Tank.
2000- Aluminum Lithium Al-Li 2195, which reduced
the weight of the External Tank by 7,500 pounds (3,402
kilograms).
Today, the External Tank project uses the new alloy to
build the Shuttle’s Super Lightweight Tanks.
 FSW Process Steps
1. Start 2. Plunge into
Spindle Material

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3. Preheat 4. Traverse
 The Process
• A rotating non-consumable cylindrical
shouldered tool with a profiled pin
penetrates the material and generates
frictional heat, softening the material
without reaching the melting point and
enabling the weld.
• The parts have to be securely clamped
to prevent the joint faces from being
forced apart
• The plasticised material, transferred to
the trailing edge of the tool pin, is
forged through intimate contact with
the tool shoulder and pin profile. On
cooling, a solid phase bond is created
between the work-pieces.

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Photographs of Welded Joints

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Different joint configuration by FSW process

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Cross section of different weld joints

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 Heat Generation during FSW

 The heat generated in the joint area takes it to

typically about 80-90% of the melting temperature.

 The heat input is purely mechanical and includes

force, friction, and rotation.

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Process Parameters

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 Process Parameters
• Tool rotation and traverse speeds
There are two tool speeds to be considered in
friction-stir welding; how fast the tool rotates and
how quickly it traverses the interface. These two
parameters have considerable importance and
must be chosen with care to ensure a successful
and efficient welding cycle.

• Tool Tilt
Tilting the tool by 2–4 degrees, such that the rear of
the tool is lower than the front, has been found to
assist this forging process. It affects the bead
characteristics and the appearance of the weld.

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 Process Parameters
• Down Force / Plunge Depth
The plunge depth is defined as the depth of the
lowest point of the shoulder below the surface of
the welded plate and has been found to be a
critical parameter for ensuring weld quality. The
plunge depth needs to be correctly set, both to
ensure the necessary downward pressure is
achieved and to ensure that the tool fully
penetrates the weld.
• Tool design
The design of the tool is a critical factor as a good
tool can improve both the quality of the weld
and the maximum possible welding speed.­It is
desirable that the tool material is sufficiently
strong, tough, and hard wearing at the welding
temperature.

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Tools

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 Tool geometry
Tool geometry is the most influential aspect of process
development. The tool geometry plays a critical role in material
flow and in turn governs the traverse rate at which FSW can be
conducted.

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Conventional threaded pin

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 Why FSW?

Source: Friction stir welding and processing R.S. Mishraa,, Z.Y. Mab
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Friction Stir Welding - Process advantages
• Low distortion, even in long welds
• Excellent mechanical properties as
proven by fatigue, tensile and bend
tests
• No fume
• No porosity
• No spatter
• Low shrinkage
• Can operate in all positions
• Energy efficient

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 Friction Stir Welding - Process advantages
• Friction stir welding can use existing and readily available
machine tool technology. The process is also suitable for
automation and adaptable for robot use. Its main advantages are:
• Non-consumable tool
• One tool can typically be used for up to 1000m of weld length in
6000 series aluminum alloys
• No filler wire
• No gas shielding for welding aluminum
• No welder certification required
• Some tolerance to imperfect weld preparations - thin oxide layers
can be accepted
• No grinding, brushing or pickling required in mass production

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 The limitations of the FSW
process 
• Welding speeds are moderately
slower than those of some fusion
welding processes (up to
750mm/min for welding 5mm thick
6000 series aluminium alloy on
commercially available machines)
• Workpieces must be rigidly clamped
• Backing bar required
• Keyhole at the end of each weld

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Challenges to FSW of Stainless
Steels

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 Challenges to FSW of SS
FSW of Stainless steel 304 had not been progressing as
rapidly as for aluminium and other metals because of
various reasons some of which are given below:
The material from which the tool is made has to
survive much more strenuous conditions because of
strength of steel and high softening temperature of
steels.
The consequences of phase transformations
accompanying FSW have not been studied in sufficient
depth.
The variety of steels available is much larger than for
any other alloy system, requiring considerable
experiments to optimize the weld for a required set of
properties
Cost Competitiveness

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 The wearing out of the
Tool after welding

One of the biggest problems with FSW,

effects of steel added: The tool is
expected to wear out quite frequently
and with steel the effects become more
and more pronounced.

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Source: Critical assessment: friction stir welding of steels H. K. D. H. Bhadeshia
and T. DebRoy
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 Addressing the concerns in FSW for
Stainless Steels
1. Tool Material
An ideal tool would be:
Strong enough even at
high temperatures
Wear Resistant to bear
brushing up a steel durably
Cheap enough for mass
production
Available options:
Diamond
PCBN (Boron Nitride)
2. Phase Effects
Arbitrary heating and
cooling of steel is well
known to produce a lot of
undesirable effects in
ferrous alloys.
So studying the effects of
stir welding owing to it’s
peculiar temperature
range on the overall
strength of a material like
steel gains importance.
3. Analysis of Joint
Finally the analysis of the
weld joint is of prime
importance, as it leads to
the technological as well as
economic results out of the
process.
Based on these tests, is it’s
feasibility weighed in terms
of it’s comparison with
other joining processes.
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 1. Tool Material Selection

Wanted in an ideal tool:

High Temperature Strength enough to be useful here

Wear Resistance and Durability to bear brushing up a

steel
Cheap enough for mass production owing to
continuous consumption

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 Post-weld analysis of the Tool
260 feet in 1018 mild steel
• Solved design issue in driving
PCBN
• 78 tool plunges
• No visible wear
• Pin fractured at 262 feet

Befo After 200

re feet

Bead on plate
performed for life study

1
5m
m

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Issues with Tool material selection
• To apply FSW in steel or other high-temperature
materials, the difficulty is mainly associated with
finding proper tool material; a material that can
withstand the high temperatures that are
experienced during the process. The
temperatures are especially high because of
steel being ferrous.
• Resistance to wear (durability) is one important
aspect, especially as many of the intended
applications are considered critical at a
microscopic level; hence there can be no traces
of the tool left in the seam. PCBN is one of the
most promising tool materials so far.

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 We want a hard material!
Why not use Diamond?
• Diamond is soluble in iron, nickel, and
related alloys at high temperatures, to
give carbides
• Blending of diamond cutting tools
into the metallic components of the
movable machinery is relatively a
harder task
• Natural diamond is very rare and
being a gemstone is quite costly while
the artificial diamond is very difficult
to manufacture.
So diamond abrasives are preferred only
for aluminium alloys, ceramics and
stone.

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 2. Phase Effects

Arbitrary heating and cooling of steel is well

known to produce a lot of undesirable effects in
ferrous alloys.
So studying the effects of stir welding owing to
it’s peculiar temperature range on the overall
strength of a material like steel gains importance.

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 Phase analysis of materials
304 Stainless Steel

500x
A typical weld bead on
304 SS

Sigma phase observed in bands

•Also observed at grain boundaries

between bands 1000
x 63
 3. Analysis of Welded
Joints

Finally the analysis of the weld joint is of prime

importance, as it leads to the technological as well as

economic results out of the process.

Based on these tests, is it’s feasibility weighed in

terms of it’s comparison with other joining processes.

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Friction Stir Welding - Applications
• Shipbuilding and marine industries
• The shipbuilding and marine industries are two
of the first industry sectors which have adopted
the process for commercial applications. The
process is suitable for the following applications:
Panels for decks, sides, bulkheads and floors
• Aluminum extrusions
• Hulls and superstructures
• Helicopter landing platforms
• Offshore accommodation
• Marine and transport structures
• Masts and booms, e.g. for sailing boats
• Refrigeration plant

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 Friction Stir Welding -
•
Applications
Aerospace industry
• At present the aerospace industry is welding prototype parts by friction stir welding.
Opportunities exist to weld skins to spars, ribs, and stringers for use in military and
civilian aircraft. This offers significant advantages compared to riveting and machining
from solid, such as reduced manufacturing costs and weight savings. Longitudinal butt
welds and circumferential lap welds of Al alloy fuel tanks for space vehicles have been
friction stir welded and successfully tested. The process could also be used to increase
the size of commercially available sheets by welding them before forming. The friction
stir welding process can therefore be considered forewings, fuselages, empennages
• Cryogenic fuel tanks for space vehicles
• Aviation fuel tanks
• External throw away tanks for military aircraft
• Military and scientific rockets
• Repair of faulty MIG welds

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