Jom Module II

Joining of Materials
(Code: MMT355)
Module-II
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Oxyacetylene Welding
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ELECTRON BEAM WELDING (EBW)
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EBW
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EBW
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EBW
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EBW
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EBW
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EBW
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EBW
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EBW
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EBW
EBW Single GMAW

Pass Multi-Pass
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EBW
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EBW
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EBW
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EBW
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EBW
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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Resistance Welding
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LBW
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LBW
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LASER BEAM WELDING (LBW)
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LBW
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LBW
Effects and possible applications of lasers under various operating

conditions.
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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LBW
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Friction Stir Welding
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A typical macrograph showing

various microstructural zones in FSP
7075Al-T651
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Functions of the Tool

The tool serves two primary
functions:
(a)heating and
(b)deformation
of work-piece material.
R.S. Mishra and Z Y Ma , Materials Science and Engineering R 50 (2005) 1–78

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Kumar et al., J. of Materials Processing Technology, Vol. 255, 2018, Pps470-476
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Flow of material in FSW
(a) Metal flow patterns and (b) metallurgical processing

zones developed during friction stir welding
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(a) A typical optical cross-section showing SZ, TMAZ, HAZ and BM. Dotted and dashed lines
show outer boundaries of TMAZ and HAZ. Color arrows indicate gradients of temperature,
strain and strain rate from low (purple) to high (red) values. (b) Optical metallograph of a
longitudinal crosssection obtained using the “stop-action” technique (pin was moving from
left to tight). The dotted line indicates the outer boundary of TMAZ. Color arrows indicate
gradients of temperature, strain, and strain rate from low (purple) to high (red) values.
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Effect of Process Parameters
Effect of depth on peak temperature as a function of distance from

weld centerline
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Effect of tool rotation rate on peak temperature as a function of

distance from weld centerline
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Variation of peak temperature with distance from weld centerline

for a 6061Al-T6 FSW weld made with and without pin
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Effect of tool rotation rate/traverse speed ratio on peak

temperature of FSW
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E
z   exp( )
RT
Pradeep and Pancholi, Materials Sci. & Eng. A 561 (2013) 78–87
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Grain size distribution in various locations of 7050Al weld nugget 101
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Applications of FSP
Examples of the industrial application of friction stir welding and processing: (a) the Eclipse
500 business jet, the first to use FSW, (b) 50 mm thick copper nuclear waste storage
canisters, (c) dissimilar FSW of aluminum to steel in Honda front subframe, (d) deckhouse
structure of Littoral Combat ship, (e) orbital FSW of steel pipes, and (f) floor panels of
Shinkansen train, FSP surface modification of h) the Nibral propeller and g) automotive
piston. 105
Applications of Friction Stir Welding
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Friction Stir Processing of Magnesium Alloys
Researchers have focused on the following aspects

of friction stir processed (FSPed) Mg alloys:
1) Modification of the cast structure by FSP
2) Preparation of the fine-grained, ultrafine-, and nano-
grained Mg alloys by FSP
3) Superplastic deformation behavior of FSPed Mg alloys
4) Preparation of Mg-based surface composites by FSP
5) FSP additive manufacturing technique.
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Magnesium Alloys
AZ91
Mg-Al Alloys
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Modification of the Cast Structure by FSP
Friction Stir Processed GZ31 Cast Alloy
(a) The dendritic microstructure of the as-cast plate, (b)

distribution of precipitates at higher magnification
M. Sabbaghian, R. Mahmudi, J. Mater. Eng. Perform. 25, 1856 (2016)
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Modification of the Cast Structure by FSP
Friction Stir Processed GZ31 Cast Alloy
The microstructure of
different regions after
two passes of FSP:
(a)SZ/TMAZ/HAZ,
(b)SZ/TMAZ,
(c)TMAZ, and
(d)Middle of SZ
M. Sabbaghian, R. Mahmudi, J. Mater. Eng. Perform. 25, 1856 (2016)
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Friction Welding
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Friction Welding
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Friction Welding
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Friction Welding
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Friction Welding
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Friction Welding
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Friction Welding
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Friction Welding
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Friction Welding
Non-Fusion Vs Fusion
Welding Processes
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Friction Welding
Non-Fusion Vs Fusion
Welding Processes
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Friction Welding
https://youtu.be/-aEuAK8bsQg
https://youtu.be/EaguF5K9I-Q
https://youtu.be/iG3t0Q7UuCU
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Joining of Materials

EBW Single GMAW

Effects and possible applications of lasers under various operating

A typical macrograph showing

Functions of the Tool

R.S. Mishra and Z Y Ma , Materials Science and Engineering R 50 (2005) 1–78

Flow of material in FSW

(a) Metal flow patterns and (b) metallurgical processing

Effect of depth on peak temperature as a function of distance from

Effect of tool rotation rate on peak temperature as a function of

Variation of peak temperature with distance from weld centerline

Effect of tool rotation rate/traverse speed ratio on peak

Researchers have focused on the following aspects

(a) The dendritic microstructure of the as-cast plate, (b)

M. Sabbaghian, R. Mahmudi, J. Mater. Eng. Perform. 25, 1856 (2016)

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