IOP Conference Series: Materials Science and Engineering

PAPER • OPEN ACCESS

A Review On Friction Stir Welding And It’s Processes

To cite this article: B Vijaya Ramnath et al 2020 IOP Conf. Ser.: Mater. Sci. Eng. 923 012030

View the article online for updates and enhancements.

This content was downloaded from IP address 103.242.189.153 on 26/05/2021 at 17:55

ICTAMDMES'20 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 923 (2020) 012030 doi:10.1088/1757-899X/923/1/012030

A Review On Friction Stir Welding And It’s Processes

B Vijaya Ramnath * , C Elanchezhain , C Vignesh,
V Sudharsan, C Selva Ganesh
Department of Mechanical Engineering, Sri Sairam Engineering College,West
Tambaram,Chennai-600 044

*E-mail: vijayaramnathb@gmail.com

Abstract. Friction stir Welding (FSW) is a solid-state joining process which

removes the common problems encountered in conventional welding
processes. FSW is normally suitable for alloys of aluminium, magnesium and
steel. Sectors like automotive, aerospace, ship building and electronics
industries are facing problems with fusion welding, since there is a huge
difference in chemical and physical properties of components to be joined. This
paper reviews the basic principle and methodology of FSW and covers all the
technical aspects like mechanical characterization, similar and dissimilar
combinations, micro structural characterization.

Keyword: Friction stir welding, mechanical characteristics, process parameters, FEA

modeling

1. Introduction
Friction Stir Welding (FSW) is a method of solid-state metal joining in which non-consumable
rotating device used for joining two plates is a specially designed pin. Instead, the device is
traversed along weld axis. The tool surface typically has dual behaviour namely heat
generation and mechanical sweeping of softened metal such as aluminium alloy. FSW is an
ideal process for producing low cost with high performance joints.

2. Review on Mechanical Properties of FSW

Shayan Eslami et al. (2017) researched during high frequency, the fatigue behaviour of the
dissimilar polymers welded in lap-joints have been observed to be failed due to fatigue stresses
and specimens failed by thermal stresses. Martin Reimann et al. (2017) performed research in
AA7075-T651, using refill friction stir spot welding, on the microstructure and mechanical
properties of keyhole repair welds. The measurements of the thermal cycle showed that high
heating levels and peak temperatures in the weld center are up to 540 deg Celsius. It was found
that a loss occurs in two types of fracture. The microstructure, mechanical properties, and
shape memory behaviour of FSW nitinol were investigated by Mani Prabu et al.(2017). Owing
to grain refinement, the yield strength of the specimen weld joint improved by 17 % compared
to the base material but the initial phase was maintained using the SMA. Sharma et al.(2017)
studied the mechanical properties of Al-Zn-Mg joints type FSW steel. The joint formed was
subjected to bend test, stiffness test, optical examination and SEM analysis. It is derived from
the regression model that the scale of the aluminium grains increases as the welding speed
rises and the rotational speed decreases. Chao Zhang et al.(2017) studied the 9 % Cr
microstructure and mechanical properties of reduced FSW joint ferritic / martensitic steel
activation. The plant refining and the martensitic transition are the two main characteristics of
the weld region's microstructure. The SiC nano-powder results of dissimilar Al-Mg alloy to
A316L Stainless Steel on the FSW were studied by Fallahi et al.(2017). For in-situ production
of the hybrid composite in the stir zone of the bi-metallic joint, the effects of Pass numbers

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
ICTAMDMES'20 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 923 (2020) 012030 doi:10.1088/1757-899X/923/1/012030

and traverse velocity on the second phase distribution, micro-structural features, and
mechanical properties of dissimilar joints were analysed. Hemath Kumar et al.(2016)
examined the mechanical behaviour of Al-based composite material for friction stir welding
and the results showed that the tension of the welded joint improved and the tensile properties
were adequate compared to the base metal. Ramesh et al.(2016) studied the characterization
of the microstructure and toughness of the friction stir welded brass plate and found that
rotational speed had a significant effect on crack forming and the frequency of dynamic re-
crystallization in the stir zone was shown by the inclusion of fine grains and higher hardness.
Shayan Eslami et al. used a newly developed method to examine the impact of friction stir
welding parameters for lap joint of dissimilar polymers. It was noticed that the welds
developed with this tool significantly improved the surface quality and strength of the welds
and the rotational and traverse speeds play the most effective role with respect to the overall
tensile strength of the specimen. Xueqi Lv et al.(2017) studied the microstructure and
mechanical properties of Al alloy and Mg alloy. They found that difference in the welding
mechanism ,weld properties and improvement in process temperature, direction material flow
and mechanical interlocking of the Al-Mg joint .

3. Review on Effect of Process Parameters of FSW

Shanavas et al., used reaction surface technique to achieve parametric optimization of friction
stir welding parameters of marine grade aluminium alloy. A defect-free weld is found in and
around the stir region from the macro-and micro-structure analysis. As a consequence of
complex re-crystallisation, grain refining occurred in the stir zone. Farzad et al.(2017) studied
the effects of processing parameters of micro-structure and mechanical behaviour’s of
underwater FSW of Al5083 alloy. The water-cooling cycle at the time of welding defined very
high cooling rate so that the grains do not have enough time to grow and shape a zone in the
welded region. Suresh et al.(2017) proposed an substitution to fusion welding to increase stress
corrosion cracking resistance maraging steel. The separation of alloying elements and
formation of reverted austenite pool where suppressed by FSW. The result shows that the
improved SCC resistance of FSW maraging steel weldments as compared to base metal.
Shayan Eslami et al.(2017) researched friction stir welded dissimilar polymers for the
assessment of fatigue existence. He conclude that in cyclic loading , the friction stir welded
joints with brittle behaviour exhibited good resistance. It was found that the experiment fell
and necked due to high level of examination and resulted in retreated side of weld. Wen-hui
Liu et al.(2017) tracked optical microscopy (OM) and X-ray diffraction (XRD) to study the
microstructure and texture evolution. The evolutions of structure of α-Mg and β-Li have also
been studied. The results showed an elongation in the phases α-Mg and β-Li, and thin laminar
sandwich structure is established. Paoletti et al.(2014) performed friction swirl spot welding
to 3 mm thick polycarbonate sheets by creating an Artificial Neural Network to anticipate the
welded area's mechanical behaviour. They concluded that Artificial neural network was used
to model the impact of friction stir spot welding parameters on the maximum plunging force,
maximum torque and joint strength of polycarbonate sheet welds.

4. Review on FEA Modeling on FSW

El-Sayed et al.(2018) used the finite element simulation of aluminium alloy AA5083-O FSW
method to estimate the temperature distribution and residual thermal stresses by
experimentally validating it using thermal image camera. They found that the peak
temperature obtained through the use of threaded device pin profile is greater than that
obtained through the use of tapered ones. Haidong et al. (2018) developed a FSW-induced
simulation analysis of welding stress. The characteristics of stress are shown in the analytical

2
ICTAMDMES'20 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 923 (2020) 012030 doi:10.1088/1757-899X/923/1/012030

results of the temperature distribution and stress evolution and it is stated that the radial stress
in the welded structure decreases with a rise in the depth of the impression and the tensile
stress decreases in the welded structure in the higher advancing speed. Noor Zaman Khan et
al. (2017) examined the flaws in the FSW clean manufacturing process. The study revealed
that the faults are induced by insufficient consolidation of material behind the pin, ineffective
heat generation and excessive movement of the material. The multiple faults such as tunnelling
faults, hooking faults, inadequate root penetration and voids are listed for their reasons and
suggestions.

5. Review on Corrosion analysis and other metal welding using FSW

Multi-criteria decision making approach for the selection of optimum process parameters for
FSW of Aluminium 2024 alloy and the optimum process parameter conditions that give
maximum response are rotational speed of 1000 rpm, welding speed of 0.08 m/min and tool
offset of 0 mm were been conducted by Sudhagar et al. (2017) . Nidhi Sharma et al.(2017)
analysed Aluminium to Copper's FSW. Work mentions the faults that occurred during the
dissimilar Al-Cu FSW, and describes the potential remedies. The thrust force and the force
component as well as the torque empowered for FSW are reported. The temperature
distribution followed by the flow stress is also studied. Kamal Jayaraj et al.(2017), investigated
the electro-chemical corrosion behavior os stir-zone of AA6061 Aluminum-AZ31B
magnesium alloy dissimilar joints. The potentio-dynamic polarization test was performed to
compare the empirical relationship of the FSW stir zone corrosion rate of dissimilar joints.
Ranvijay Kumar et al.(2018) investigated the weldability of FSW thermo-plastic materials. It
was observed that the selection of pin profile shoulder diameter, reasonable speed, travel
speed, tilt angle, plunge depth are the input parameters to be selected with optimum material
flow and heat generation. Hou Longgang et al.(2017) studied the corrosion behavior of FSW
Al-Mg-Zn alloys and the impact of pre-welded temperature conditions on the FSW alloy's
corrosion behaviour. It was found that with the increase in the zinc content, both maximum
corrosion depth and dominated corrosion mode differs in different welding regions after heat
treatment and post-welding.

6. Conclusion
This paper discusses various aspects of FSW such as Tool Geometry, different materials,
gripping device (Fixture), optimization technique, temperature distribution, process impact on
the environment, fracture mode, micro-structure and various mechanical properties of different
materials. This research article also discusses Numerical analysis of FSW as well as the latest
trends. But there are still there are some issues left to debate in Numerical analysis. For
industrial applications, therefore, it can be assumed that FSW is an economical and
environmentally friendly welding process.

REFERENCES

[1] Shayan Eslami, Poulo J Taveres, P MG P Moreira, “Fatigue Life Assessment of

Friction Stir Welded Dissimilar Polymers”, 2 nd International Conference on
Structural Integrity,(4-7), pp. 1433-38, 2017.M.B. Karamis , A. Tasdemirci, F. Nair
// Failure and tribological behaviour of the AA5083 and AA6063 composites
reinforced by SiC particles under ballistic impact, 34 (2003) 217–226

3
ICTAMDMES'20 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 923 (2020) 012030 doi:10.1088/1757-899X/923/1/012030

[2] Martin Reimann, Jannik Goebel, Jorge F. dos Santos, “Microstructure and Mechanical
Properties of keyhole repair welds in AA7075-T651 using refill Friction Stir
Welding”, Materials and Design, (132), pp.283-294, 2017.
[3] S.S.Mani Prabu, H.C.Madhu, Chandra S.Perugu, K.Akash, P.Ajay Kumar, Satish,
V.Kailas, Manivannan, Anbarasu, I.A.Palani, “Microstructure, Mechanical Properties
and shape memory behaviour of Friction Stir Welding nitinol”, Materials Science and
Engineering A, (693), pp.233-236, 2017.
[4] C.Sharma, C.Upadhyay, D.K.Dwivedi, P.Kumar, “ Mechanical Properties of Friction
Stir Welding armor grade Al-Zn-Mg alloy joints”, Transactions of Non-Ferrous
Metals Society Of China, (27), pp.493-506, 2017.
[5] Chao Zhang, Lei Cui, Yongchang Liu, Chenxi Liu, Huijun Li, “ Microstructure and
Mechanical Properties of Friction Stir Welding on 9% Cr reduced activation
ferritic/martensitic steel”, Journals of Materials Science and Technology, 2017.
[6] A.A.Fallahi, A.Shokuhfar, A.Ostovari Moghaddam, A.Abdolahzadeh, “ Analysis of
SiC nano-powder effects on Friction Stir Welding of dissimilar aluminium-
magnesium alloy to A316L stainless steel”, Journal of Manufacturing Processes, (30),
pp.418- 430, 2017.
[7] G. Hemath Kumar1, Babu Vishwanath1, Rajesh Purohit, R. S. Rana and Saurabh
Singh Rajpurohit, “Mechanical Behaviour Of Friction Stir Welding On Aluminium
Based Composite Material”, 6th International Conference of Materials Processing and
Characterization, (4), pp.5336–5343, 2017.
[8] Ramesh Ga, Srimuthunath Ib, Santha Kumar Nb, Sugandipriya Sb, Aravindhan V,
“Characterization of microstructure and hardness of friction stir welded brass plate”,
6th International Conference of Materials Processing and Characterization, (5),
pp.2721–2725, 2018.
[9] Shayan Eslami, Paulo J Tavares, P M G P Moreira, “Fatigue life assessment of friction
stir welded dissimilar polymers”, 2nd International Conference on Procedia Structural
Integrity, (5), pp.1433-1438, 2017.
[10] Xueqi Lv, ChuanSong Wu, Chunliang Yang, G.K. Padhy, “Weld microstructure and
mechanical properties in ultrasonic enhanced friction stir welding of Al alloy to Mg
alloy”, Journal of Materials Processing Tech. (254), pp.145–157, 2018
[11] S.Shanavas, J.Edwin Raja Dhas, “ Parametric optimization of Friction Stir Welding
parameters of marine grade Aluminium alloy using response surface methodology”,
Transactions of Non-Ferrous Metals Society Of China, (27), pp.2334-44, 2017.
[12] Farzad Heirani, Alireza Abasi, Mohammad Ardestani, “Effects of processing
parameters on Microstructure and Mechanical Properties of underwater Friction Stir
Welding of Al5083 alloy”, Journal of Manufacturing Processes, (25), pp.77-84,
2017.
[13] Suresh.D.Meshram, Archana G.Paradkar, G.,Madhusudhan Reddy, Sunil Pandey,
“Friction Stir Welding: An alternative to fusion welding for better stress corrosion
cracking resistance of maraging steel”, Journal of Manufacturing Processes, (25),
pp.94-103, 2017.
[14] Shayan Eslamia , Tiago Ramosa, Paulo J. Tavaresa, P. M. G. P. Moreira “Effect of
friction stir welding parameters with newly developed tool for lap joint of dissimilar
polymers”, Procedia Engineering, (114),pp. 199 – 207, 2015.
[15] Wen-hui Liu , Xiao Liu , Chang-ping Tang , Wei Yao , Yang Xiao , Xu-he Liu,
“Microstructure and texture evolution in LZ91 magnesium alloy during cold rolling”,
Journal of Magnesium and Alloys, 2017.
[16] A. Paoletti, F. Lambiase, A. Di Ilio, “Optimization of friction stir welding of
thermoplastics”, Procedia CIRP, (33),pp.562 – 567, 2015.

4
ICTAMDMES'20 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 923 (2020) 012030 doi:10.1088/1757-899X/923/1/012030

[17] M.M.El-Sayed, A.Y.Shash, M.Abd-Rabou, “Finite element modeling of aluminium

alloy AA5083-O Friction Stir Welding process”, Journal of Materials Processing
Tech, (252), pp.13-24, 2018.
[18] Haidong Yu, Bin Zheng, Xinmin Lai, “ A modeling study of welding stress induced
by Friction Stir Welding”, Journal of Materials Processing Tech, (254), pp.213-220,
2018.
[19] Noor Zaman Khan, Zahid A.Khan, Arshad Noor Siddiquee, Abdulrahman M.Al-
Ahmari, Mustafa H.Abidi, “Analysis of faults in clean fabrication process of Friction
Stir Welding”, Transactions of Non-Ferrous Metals Society Of China, (27), pp.1507-
16, 2017.
[20] S.Sudhagar, M.Sakthivel, Prince.J.Mathew, S.Ajith Arul Daniel, “A multi-criteria
decision making approach for process improvement in Friction Stir Welding of
aluminium alloy”, Measurement, (108), pp.1-8, 2017.
[21] Nidhi Sharma, Zahid A.Khan, Arshad Noor Siddiquee, “Friction Stir Welding of
aluminium to copper-An overview”, Transactions of Non-Ferrous Metals Society Of
China, (27), pp.2113-36, 2017.
[22] R.kamal Jayaraj, S.Malarvizhi, V.Balasubramanian, “ Electro-Chemical corrosion
behavior of stir zone of Friction Stir Welding dissimilar joints of AA6061 aluminium-
AZ31B magnesium alloys”, Transactions of Non-Ferrous Metals Society Of China,
(27), pp.2181-92, 2017.
[23] Ranvijay Kumar, Rupinder Singh, I.P.S.Ahuja, Rosa Penna, Luciano Feo, “
Weldability of thermo-plastic materials for Friction Stir Welding-A state of art review
and future applications”, Composites Part B, (137), pp.1-15, 2018.
[24] Hou Longgang, Yu Jiajia, Zhang Di, Zhuang Linzhong, Zhou Li, Zhang Jishan,
“ Corrosion Behaviour of Friction Stir Welding Al-Mg-Zn alloys”, Rare Metal
Materials and Engineering, (46), pp.2437-44, 2017.