FRICTION STIR WELDING

FRICTION-STIR WELDING (FSW)

Is a solid-state joining process , This process is primarily used on aluminum,
most often on large pieces which cannot be easily heat treated post weld to recover temper characteristics.

 It was invented and experimentally proven by Wayne Thomas and a team of his colleagues at The Welding Institute UK in December 1991. TWI holds a number of patents on the process, the first being the most descriptive,

PRINCIPLE OF OPERATION
Schematic diagram of the FSW process:

 Two discrete metal work pieces butted together, along with the tool (with a probe).
In FSW, constant speed and fed.

At a constant traverse rate into the joint line between two pieces of sheet or plate material, which are butted together.

(B) The progress of the tool through the joint

 The parts have to be clamped rigidly on to a backing bar. In a manner that prevents the abutting joint faces from being forced apart. The length of the nib is slightly less than the weld depth required. And the tool shoulder should be in intimate contact with the work surface. the nib is then moved against the work, or vice versa.

 Frictional heat is generated between the wear-resistant frictional stirred materials to soften without reaching the melting point weld line in a plasticised tubular shaft of metal. The welding of the material is facilitated by severe plastic deformation in the solid state, involving dynamic recrystallization of the base material

ADVANTAGES
solidification cracking and liquation cracking are not an issue during FSW. low concentration of defects and is very tolerant to variations in parameters and materials. Any problems associated with cooling from the liquid phase are immediately avoided.

DISADVANTAGES
FSW is associated in more defects: Insufficient weld temperatures,

This may result in long,

Reduce the continuity of the bond between the material from each side of the weld.

Potential advantages of FSW over conventional fusion-welding processes

Good mechanical properties in the as welded condition Improved safety due to the absence of toxic fumes or the spatter of molten material. No consumables - conventional steel tools can weld over 1000m of aluminium and no filler or gas shield is required for aluminium.

 Easily automated on simple milling machines lower setup costs and less training. Can operate in all positions (horizontal, vertical, etc), as there is no weld pool. Generally good weld appearance and minimal thickness under/over-matching, thus reducing the need for expensive machining after welding. Low environmental impact.

Disadvantages
Exit hole left when tool is withdrawn. Large down forces required with heavy-duty clamping necessary to hold the plates together. Less flexible than manual and arc processes. Often slower traverse rate than some fusion welding techniques although this may be offset if fewer welding passes are required.

APPLICATIONS
welding of the aluminum main Space Shuttle external tank, Orion Crew Vehicle test article. Boeing Delta II and Delta IV Expendable Launch Vehicles. SpaceX Falcon 1 rocket, armor plating for amphibious assault ships. welding the wings and fuselage panels of the new Eclipse 500 aircraft from Eclipse Aviation.

THANK YOU