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Materials Today: Proceedings 4 (2017) 8901–8910 www.materialstoday.com/proceedings

ICAAMM-2016

Low Cost Friction Stir Welding: A Review

Gurunath Shindea*, Sameer Gajghateb, Dr.P.S.Dabeerc, Dr.C.Y. Seemikerid,
a
Ph D Research Scholar, G.H.Raisoni College of Engineering and Management, Pune(India)
b
Ph D Research Scholar, Dr. Daulatarao Aher College of Engineering,Karad(India)
c
Principal, Trinity College of Engineering and Research, Pune(India)
d
Professor, Govt. Polytechnic, Ratnagiri (India)

Abstract

Friction Stir Welding is a solid state welding process which is used to join the soft materials like aluminium, copper, nickel,
titanium etc. It uses heat generated from friction produced by rotating tool and high axial force. At elevated temperature material
undergoes plastic deformation zone which is stirred by rotating tool. On cooling, a solid bond is formed, it is called as weld
nugget.FSW Process is characterized by different welding parameters like Rotation Speed, Traverse Speed, Axial load, Tool
Geometry which enhances different mechanical properties such as tensile strength, yield strength, hardness, corrosion resistance
etc. This paper shows effect of various welding parameters on the characteristics of weld formed during FSW.

© 2017 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility ofthe Committee Members of International Conference on Advancements in
Aeromechanical Materials for Manufacturing (ICAAMM-2016).

Keywords Solid State Process; Plastic Deformation; Weld Nugget

1. Introduction
Friction Stir Welding (FSW) is an advanced technique to join soft materials like aluminium, copper, nickel,
titanium etc which are difficult to join by traditional welding methods. It is invented by W.Thomas and E Nicholas
at The Welding Institute (TWI), Cambridge, UK in 1991.FSW is a solid state welding process which uses a non
consumable rotating tool with small probe at its end. Rotating tool serves two main functions 1.Heat can be
produced by large axial force and high RPM required to soften metal 2.Stirring of materials to form weld nugget by
*Corresponding author.
E- mail address: gurunathshinde@yahoo.com

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility ofthe Committee Members of International Conference on Advancements in
Aeromechanical Materials for Manufacturing (ICAAMM-2016).
8902 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910

making solid bond on cooling. During the process, material undergoes in a plastic deformation phase at high
temperature which forms fine and equaxed recrystallized grains. Due to fine and recrystallization grains mechanical
properties such as tensile strength, yield strength, hardness, elongation etc can be improved (Fig. 1).

Fig.1.Friction Stir Welding (FSW) Process

This technology is said to be low cost because of following benefits:

• It can be used with conventional vertical milling machine.
• It utilizes simple, non-consumable and economical tooling.
• No filler material or shielding gas is required to join the material.
• As the soft material used for joining, less energy required to weld.
• No special purpose and costly fixture is required for holding the work piece.
During the process following zones are observed as shown in fig.2.,
• Weld Nugget (WN): It is the metal structure formed after cooling of stirred zone which creates strong bond
between the two metals under the welding. Recrystallized fine grain structures in the form of onion rings are
observed.
• Heat Affected Zone (HAF): This zone experiences a thermal cycle, but does not undergo any plastic
deformation. It retains the same grain structure as the parent material
• Thermo-Mechanically Affected Zone (TMAZ): It is highly deformed zone. The base metal contains elongated
grains were deformed in an upward flowing pattern around the nugget zone. Although the TMAZ underwent
plastic deformation, recrystallization did not occur in this zone due to insufficient deformation strain.
• Base Material (BM): The unaffected zone which does not experience effect of welding parameters.
 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910 8903

Fig.2.Different Zones in FSW Process

2. Literature Review:

Fuji et al.[1] performed butt welding of 1050-H24, 5083-O and 6061-T6 aluminium alloys. Tools with columnar
probe with threads and without threads, triangular prism were used during the experiment. Study reveals that for
high melting temperature metal, when deformation resistance is low a columnar tool without threads will be
effective whereas when deformation resistance is high a columnar tool without threads can provide sound weld by
decreasing the rotation speed. Wei et al.[2] conducted experiments on 2mm thick 01420 Al-Li alloy plates with
different welding parameters pin rotation, welding speed, welding pressure. Groove type defect was observed at low
speed welding. At very high speed surface quality became poor; groove type defect could be seen. At inappropriate
speed, tunnel type defect could be observed. At high axial pressure, it would be caused depression and wavy burrs.
At low axial pressure tunnel and groove type defect occurred. At small shoulder value frictional heat input was low.
It was found that hardness value was high in stir zone than base metal. Hardness tended to decrease with an increase
in heat input due to different thermal effects with welding conditions. Very fine equaxed recrystalised grain
structure was obtained in stir zone after dynamic recryastalization. Heat input had little influence on joint strength.
Elangovan et al [3] studied effect of axial force and tool pin profile on friction stir processing zone formation in
AA6061 aluminium alloy. In case of straight and tapered cylindrical pin profile, joint fabricated at an axial force of
6 kN was found to be defective whereas joints fabricated with threaded cylindrical pin profile and square pin and
triangular pin profile tool were found to be free from any kind of defects irrespective of axial force. Joints fabricated
with square and triangular pin profile tool showed superior tensile properties irrespective of axial load whereas
joints fabricated with straight cylindrical pin profile tool showed inferior tensile properties. Zhang et al. [4] carried
experiments in underwater conditions of AA2219 alloy. Tensile strength of the joint was found to be improved from
axial load of 324 MPa by external water cooling action in normal to 341 MPa with deterioration of plasticity of weld
nugget. Underwater joint was found to be fractured at the interface between NZ and TMAZ on advancing side
during tensile test. Underwater FSW joint exhibits lower hardness in NZ and Higher Hardness in TMAZ and HAZ
when compared with normal FSW. Zhang et al. [5] has studied effect of water cooling on the performance weld
quality in heat affected zone. Heat affected zone is generally intrinsic weakest location of normal friction stir welded
precipitate hardened aluminium alloy. In order to improve mechanical properties of HAZ by controlling temperature
level, underwater friction stir welding (UFSW) conditions are used. Width obtained in UHAZ is smaller than NHAZ
where as hardness found to be higher in UHAZ than NHAZ. Normal joint with tensile strength 324 MPa was
fractured in HAZ adjacent to TMAZ in tensile test. Tensile strength of 341 MPa obtained during water cooling was
8904 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910

found to be more than normal welding. Underwater joint fractured nearly along TMAZ interface rather than HAZ.
Patil et al. [6] investigated effects of different welding speed and tool pin profiles on the weld quality of AA6082-O
aluminium where tool rotation was kept constant. Joint fabricated with taper screw thread pin exhibits superior
tensile strength than tri-flute pin irrespective of welding speed. Taper screw thread joints fabricated at weld speed of
70 mm/min shows more ultimate and yield strength than weld speed at 60 mm/min and 75 mm/min. Four flute joints
fabricated at a welding speed of 60mm/min shows superior properties than 70 mm/min or 85 mm/min. Biswas et al.
[7] studied effect of geometry of tool pin and effect of tool rotation and welding speed on the mechanical properties
of friction stir welding of commercial grade aluminium alloy. It was observed that strain rate of the plasticized
material was increased with increase in tool rotation at given weld speed thus affecting the resulting microstructure
of stirred zone. Decrease in hardness was observed when weld speed was increased from 80 to 160 mm/min.
Maximum reduction in hardness was observed in case of threaded, conical and trapezoidal pin profile. Samples
welded with tapered, cylindrical and trapezoidal pin geometries exhibit 50% increase in the ductility compared to
that of base metal. Koilraj et al. [8] carried out joining of dissimilar Al-cu alloy AA2219-T87 and Al-Mg alloy
AA5083-H321 with taguchi L16 orthogonal design of experiments. He found that fusion welding of dissimilar
aluminium alloys was very challenging due to formation of low melting eutectic by constituent element resulting in
cracking. Significant drop in hardness from AA2219 unaffected base material to weld nugget on advancing side
have been observed. On retreating side only slight drop in hardness was observed from weld nugget AA5083
unaffected base material. In tensile test three weld specimens failed in AA5083 side HAZ. High strength joint can be
obtained by placing base material on advancing side. Cylindrical threaded tool profile found to be best during
welding. D/d ratio played an important role and contributes to 60 % to the weld strength. Elatharasan et al. [9]
investigated effect of rpm, weld speed and axial force on tensile strength, yield strength and displacement during
welding of AA6061 -T6 and AA7075-T6.It was observed that ultimate tensile strength is less than base metal.
Increase in rpm and weld speed showed increase in ultimate tensile strength upto a point which thereafter decreased.
Yield strength of FSW joint decreased with increase in axial load and tool feed rate. Displacement of joints
decreased with increase in tool rotation speed and weld speed. Tutar et al. [10]conducted study on non heat treatable
AA3003-H12 aluminum alloy sheets to find optimum welding conditions using taguchi orthogonal array with due
consideration of tensile shear load. Three different parameters rotational speed, plunge depth and dwell time were
considered during the study. Plunge depth was found to be the most significant parameter with contribution of 69.26
%.As plunge depth was increased; tensile shear load of fsw joint also increased with expansion of HAZ, TMAZ and
SZ zones. All fractures of the joints in tensile testing occurred in SZ, where bonding section size was small.
Hardness in SZ decreased as the tensile shear load increased. Fine grain structure in the SZ was found at higher
hardness value. Rambabu et al. [11] conducted study on aluminium alloy AA2219 (Al-Cu-Mg alloy) which has high
strength to weight ratio and good corrosion resistance properties. GilliAC electrochemical system was used for
potentiodynamic polarization to study corrosion behaviour. The response function corrosion resistance (CR) of the
joints is a function of tool profile (P), Tool rotation speed (N), Welding speed(S) and axial force (F),
CR=f (P, N, S, F)
Best quality weld was acquired using hexagon tool profile which showed fine grain structure with speed of 1300
rpm, traverse of 880 mm/min and, axial force 12 KN. Simulated annealing algorithm technique was used to optimize
the mathematical model. Kumar et al. [12] investigated effect of rotational speed, weld speed, axial load, on tensile
strength and % elongation during welding of dissimilar aluminium AA5083-O and 6061-T6. Study revealed that
increase in RPM, axial load and welds speed increases tensile strength upto a point further increase in rpm, axial
load and weld speed decreased the tensile strength. It was observed that increase in tool rotation and axial force
resulted in increase in percentage elongation whereas increase in welding speed resulted in decrease of percentage
elongation. Satish et al.[13] studied friction stir welding of commercially available pure grade aluminium and
copper. It was found that at low friction pressure with moderate upset pressure, burn off length, speed gives higher
tensile strength. It was observed that hardness in the weld zone is a higher than in heat affected zone due to the
 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910 8905

recrystallization of grains in the weld zone. Brittle intermetallics are formed due to the poor ductility of order 0.5-
1.0 %.Kadaganchi et al.[14] formulated a mathematical model with spindle speed, welding speed, and tilt angle and
tool geometry to predict the yield strength, tensile strength, % elongation of friction stir welds of AA2014-T6
aluminium alloy. Hexagonal tool profile produces higher pulsating effect and smooth material flow which resulted
in improved mechanical properties, whereas conical tool profile produced the lowest mechanical properties. Increase
in tool tilt angle led to better consolidation of material which improved mechanical properties. When welding
parameters were not appropriate defects like turbulence, warm hole, tunnel effect, crack, excess flash and thinning
of weld were observed. Flat faced tools produced pulsating effect and better plastic flow. Welding defects can be
eliminated by increasing tool tilt angle. Papahn et al. [15] studied effect of cooling media on the residual stresses
induced by solid state welding process scrutinized through measuring and comparing RS caused by underwater and
immersed FSW using ultrasonic method for AA7075-T6.Water media can reduce longitudinal residual stresses to 82
% in the nugget zone. Residual stresses in the longitudinal direction were four times larger than that of transverse
direction for both air and underwater medium. Longitudinal residual stress was tensile inside nugget while it was
compressive outside of nugget. Residual stress was about 17% greater in the advancing side as compared to the
retreating side. Palanivel et al. [16] studied effect of welding speed on mechanical and metallurgical properties of
dissimilar welding of AA5083-H111 and AA6351-T6 aluminium alloys. Three kinds of microstructures have been
observed, namely unmixed region, mechanically mixed region and mixed flow region. The fracture mode was
observed to be a ductile fibrous fracture. In general; FSW at higher welding speeds results in a short exposure time
in the weld area with insufficient heat and poor plastic flow of the metal and causes some voids like defects in the
joints. The increase in welding speed leads to the increase in the tensile strength up to the maximum value, while
further increase in welding speed results in the decrease in the tensile strength of FS welded joints. Lower welding
speeds cause improper consolidation of material, which leads to the reduction in UTS owing to the defect. The
stirring becomes insufficient at higher welding speeds. The material present in the advancing side of the tool does
not travel enough to the retreating side, which causes a defect. Sanusi et al. [17] carried friction stir welding of
commercial pure copper by varying rotational speeds. Samples processed at rotational speed of 1200 rpm have the
lowest corrosion potential and behave worse than 1600 and 2000 rpm processed samples. The inclusion of residuals
from the tools may contribute to the corrosion potential for the Sample processed at 1200 rpm. The formation of
fine, equiaxed grains that are larger than those of the base metal and uniformly distributed, very fine strengthening
precipitates in the weld region were observed in the stir zone. Defects were observed and it shows the hook at the
edge of the stir zone in the FSSW joint at the edges of joint interface of the welded specimen. It can be attributed to
insufficient material flow during the stirring process. Barekatain et al. [18] studied joining of AA 1050 aluminium
alloy and commercially pure copper. The annealed and severely plastic deformed sheets were subjected to friction
stir welding (FSW) at different rotation and traverse speeds. It was observed that traverse speed range of 50-100
mm/min and rotation speeds of more than 900 r/min produce welds with appropriate surface in annealed sample.
Rotation speed of more than 1000 r/min produces welds with appropriate surface in CGPed (Constrained Groove
Pressing) samples. This may result from higher strength of CGPed that required higher heat input. The average grain
size in the stir zone is finer than that in the base metal. This grain refinement during FSW process leads to greater
hardness in the stir zone in comparison with hardness of Al base metal. Several forms of intermetallic compounds
are found in weld zone of FSWed annealed and CGPed samples. These compounds mainly consist of Al2Cu and
Al4Cu9.Lokesh et al. [19] carried out friction stir welding of AA 6063 alloy under the submerged condition to
obtain the optimum welding condition for maximum hardness. The most important factors that influence the
Submerged FSW process was the tool pin profile with 40% contribution rate and the percentage of error is 4%.The
hardness value of the welded metal is higher than the base metal at the stir zone. Dhancholia et al. [20] examined
welding of AA 6061 and AA 7039Aluminum alloys. The weld produces at low speed have good mechanical
properties than the weld produces at higher speed. The mechanical properties increase with the rotational speed and
welding speed but up to a certain level then they start decreasing.
8906 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910

Dhancholia et al. [20] examined welding of AA 6061 and AA 7039Aluminum alloys. Welding speed and Rotational
speed parameters are varied for the study whereas tensile strength, yield strength, hardness were measured. The
weld produces at low speed have good mechanical properties than the weld
produces at higher speed. The mechanical properties increase with the rotational speed and welding speed but up to
a certain level then they start decreasing. Multi objective optimization using Response Surface Methodology (RSM)
is used to optimize the friction stir welding parameters to obtain the optimum ultimate tensile strength, yield
strength, hardness value and impact strength of dissimilar friction stir welded joint at 95% confidence level.

Table.1. Literature Summary.

Authors Materials Tool Geometry Tool Material Welding Parameters Remark

For high melting temperature

metal, when deformation
resistance is low a columnar tool
Columnar probe RPM,
without threads will be effective
with threads and
Fuji et al AA1050-H24, - whereas when deformation
without threads, Weld Speed,
resistance is high a columnar tool
AA5083O, triangular prism Revolutionary pitch
without threads can provide
sound weld by decreasing the
AA6061-T6 rotation speed.

Hardness value was high in stir

zone than base metal. Hardness
01420 Al-Li Flat shoulder, RPM, Weld Speed, tends to decrease with an increase
Wei et al 1Cr18Ni9Ti
alloy Frustum Shape Weld Pressure in heat input due to different
thermal effects with welding
conditions.

straight cylindrical, Square and triangular pin profile

tapered cylindrical, tool showed superior tensile
Elangovan et axial force and tool pin
AA6061 threaded cylindrical, High carbon steel properties whereas straight
al profile
triangular and cylindrical pin profile tool
square showed inferior tensile properties.

Underwater FSW joint exhibits

lower hardness in NZ and Higher
Conical right hand RPM, Weld Speed,
Zhang et al AA2219-T6 W6Mo5Cr4V2 Hardness in TMAZ and HAZ
screwed pin Axial load
when compared with normal
FSW

Width obtained in UHAZ is

Conical right hand RPM, Weld Speed, smaller than NHAZ where as
Zhang et al AA2219-T6 W6Mo5Cr4V2
screwed pin Axial load hardness found to be higher in
UHAZ than NHAZ

Joints with taper screw thread pin

Triflute and Taper 0.3Si2C0.3Mn12.1C Weld speed, Tool Pin exhibits superior tensile strength
Patil et al AA6082-O
Screw threaded pin r Profile than tri-flute pin irrespective of
welding speed

Cylinder, Tapered, Max. Reduction in hardness was

Tool
Commercial observed in case of threaded,
Biswas et al SS310 geometry,RPM,Weld
Grade Al alloy Trapezoidal, conical and trapezoidal pin
Speed
profile. Samples welded with
Hexagonal, tapered, cylindrical and
 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910 8907

Threaded trapezoidal pin geometries exhibit

50% increase in the ductility
compared to that of base metal

Cylindrical
Cylindrical threaded tool profile
found to be best during welding.
AA2219-T87, (Straight,Tapered,Th H13 with hardness RPM, Weld Speed,
Koilraj et al D/d ratio played an important role
AA5083-H321 readed, 55VHN Pin Geometry, D/d
and contributes to 60 % to the
weld strength.
Tapered Threaded)

Increase in rpm and weld speed

showed increase in ultimate
tensile strength upto a point
Elatharasan AA6061 -T6, RPM, Weld Speed,
- - which thereafter decreased. Yield
et al AA7075-T6 Axial Force
strength of FSW joint decreased
with increase in axial load and
tool feed rate.

As plunge depth was increased;

Plunge depth,
Threaded H13 hot work tool tensile shear load of fsw joint also
Tutar et al AA3003-H12
Cylindrical Pin steel increased with expansion of
Dwell time, RPM
HAZ, TMAZ and SZ zones.

Conical ,Square,
Triangular, Tool profile, RPM, Best quality weld was acquired
Rambabu et
AA2219T87 - Weld Speed, Axial using hexagon tool profile which
al
Pentagonal, Force showed fine grain structure
Hexagonal

Increase in RPM, axial load and

welds speed increases tensile
strength upto a point further
decreases the tensile strength.
AA5083-O and RPM, Weld Speed, Increase in tool rotation and axial
Kumar et al Cylindrical -
AA6061-T6 Axial Force force resulted in increase in
percentage elongation whereas
increase in welding speed
resulted in decrease of percentage
elongation.

At low friction pressure with

moderate upset pressure, burn off
length, speed gives higher tensile
Pure grade Al Friction Pressure,
strength. Hardness in the weld
Satish et al - - Upset Pressure, Burn
zone is a higher than in heat
and Cu off length, RPM
affected zone due to the
recrystallization of grains in the
weld zone.

Hexagonal tool profile produces

Conical, Triangular, higher pulsating effect and
Square, RPM, Weld Speed, smooth material flow which
Kadaganchi
AA2014-T6 H13 tool steel Tilt angle, Tool Pin resulted in improved mechanical
et al
Pentagonal, Profile properties, whereas conical tool
Hexagonal profile produced the lowest
mechanical properties. Welding
8908 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910

defects can be eliminated by

increasing tool tilt angle.

Water media can reduce

longitudinal residual stresses to
82 % in the nugget zone. Residual
stresses in the longitudinal
direction were four times larger
than that of transverse direction
for both air and underwater
Papahn et al AA7075-T6 Treated tapered tool H13 Heat treated RPM, Weld Speed
medium. Longitudinal residual
stress was tensile inside nugget
while it was compressive outside
of nugget. Residual stress was
about 17% greater in the
advancing side as compared to
the retreating side.

Lower welding speeds cause

improper consolidation of
material, which leads to the
reduction in UTS owing to the
high carbon and
defect. The stirring becomes
high
insufficient at higher welding
AA5083-H111,
Palanivel et Straight square (SS) Weld speed, speeds. The material present in
chromium steel
al pin profile the advancing side of the tool
AA6351-T6 (HCHCr)
RPM is constant does not travel enough to the
retreating side, which causes a
oil hardened
defect. The tendency of the tool
to drag at higher welding speeds
also contributes to the lower
UTS.

The inclusion of residuals from

the tools may contribute to the
corrosion potential for the sample
processed at 1200 rpm. samples
Sanusi et al C11000 Tapered - RPM processed at rotational speed of
1200 rpm have the lowest
corrosion potential and behave
worse than 1600 and 2000 rpm
processed samples.

Welding heat input caused grain

growth and decrease in hardness
value at Al side of the stir zone. It
was found that, generally the
weakest parts of weld joints of
Barekatain et
AA 1050 Cylindrical H13 tool steel RPM, Weld Speed annealed and CGPed samples
al
were Al base metal and stir zone,
respectively. Further
investigations showed that several
forms of intermetallic compounds
were produced.

Cylindrical Tool pin profile, rotational speed

H13 tool steel Tool Pin Profile,
Lokesh et al AA6063 and welding speed contribute
hardened up to 60
(Flat, Tapered, 40%, 21% and
 Gurunath Shinde / Materials Today: Proceedings 4 (2017) 8901–8910 8909

Threaded) HRC RPM, 35%respectively.The most

important factors that influence
Weld Speed the Submerged FSW process was
the tool pin profile with 40%
contribution.
The weld produces at low speed
have good mechanical properties
than the weld produces at higher
AA 6061 and Cylindrical
Dhancholia speed. The mechanical properties
HSS tool RPM, Weld Speed
et al increase with the rotational speed
AA 7039
and welding speed but up to a
certain level then they starts
decreasing.

Conclusions
In this paper a study of friction stir welding process has been done. It is revealed that FSW can be used to weld
soft materials like aluminium, copper, nickel; titanium etc. successfully.FSW is significantly affected by various
welding parameters like rotation speed, weld speed, axial load, and tool geometry etc. Table.1. shows summary of
literature review of FSW process being applied to the soft materials. Based on review following conclusions has
been drawn-
• Increase in rotational speed (RPM), Weld speed and axial load increases tensile strength up to a point further
increase in rotational speed (RPM), Weld speed and axial load decreases the tensile strength.
• Increase in tool rotation and axial force resulted in increase in percentage elongation whereas increase in
welding speed resulted in decrease of percentage elongation.
• Ratio of shoulder diameter to pin diameter (D/d) plays an important role and contributes to the strength of
weld.
• Tool pin profile is important factor that influences Submerged FSW.
• Hardness in weld zone is higher than heat affected zone due to the recrystallization of grains in weld zone.
• Hardness in UHAZ is higher than NHAZ.
• Water media reduces residual stresses in the nugget zone as compared to the normal FSW.

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