Introduction to Friction Stir Welding (FSW)

• Friction stir welding (FSW) was invented at

The Welding Institute (TWI) of UK in 1991 as
a Solid-state joining technique.

• A non-consumable rotating tool with a

specially designed pin and shoulder is
inserted into the abutting edges of plates to
be joined and traversed along the line of joint
shown in Fig.
SCHEMATIC DIGRAM OF FSW
FSW Tool Profile
Schematic Representation of FSW
Principal of FSW
 Functions of tool

The tool serves two primary functions:

(a)Heating of work piece, and

(b) Movement of material (stirring) to produce

the joint.
 Tools profiles
1. Left-hand threaded cylindrical pin (Fig-1)
2. Cylindrical pin (Fig-2)
3. Tapered cylindrical pin (Fig-3)

Fig-1 Fig-2 Fig–3

Different Tool Designs of FSW
 Key benefits of FSW
Metallurgical benefits
1. Solid phase process
2. Low distortion of work piece
3. Good dimensional stability & repeatability
4. No loss of alloying elements
5.Excellent metallurgical properties in joint area
6.Fine microstructure
7. Absence of cracking
8.Replace multiple parts joined by fasteners
 Environmental benefits

1. No shielding gas required

2. No surface cleaning required
3. Eliminate grinding wastes
4. Eliminate solvents required for degreasing
5.Consumable materials saving, such as wire or any
other gases.
 Energy benefits

1. Improved materials use (eg. Joining different

thickness) allows reduction in weight.
2. Decreased fuel consumption in light weight
aircraft, automotive and ship applications.

2. Only 2.5% of the energy needed for a laser

weld is adequate for FSW
 Applications

1. Automotive (Wheel rims)

2. Aerospace(Fuel tanks of space vehicles)
3. Shipbuilding(Hulls and superstructures)
4. Defence (Helicopter landing Platforms)
5. Recreation(Sailing boats)
6. Transportation (Aluminium bridges)
7. Containers (Truck bodies)
 Limitations
1. Workpieces must be rigidly clamped.
2. Backing bar required.
3. Keyhole at the end of each weld.
 Types of defects in FSW
1. Lack of penetration
2. Kissing bonds
3. Worm holes
4.Porosity
5. Root toe defects
Fixture for FSW
Different weld zones
 Methodology

Procurement of Welding trials and establishing of parameter

materials, design and windows
fabrication of tools

Based on results, Development of correlations between process

parameters, microstructures and Mechanical Properties
Dimension of Un-Notched Fatigue
Specimen