Investigation Of Process

Parameters On Steel Using

Friction Stir Welding

by
bhanu pratap
M-tech ME
 INTRODUCTION

.
• FSW was invented by Wayne Thomas in 1991 at THE
WELDING INSTITUTE (TWI) England.
• It is a solid state welding process.
• It is also a cleaner and more efficient process compared to
conventional technique
• Does not require any filler material.
• It is a environmental friendly joining (fabrication) process.
 PROCESS
• A rotating non consumable cylindrical
shoulder tool with a profiled pin penetrates
the material and generates a frictional heat
• The heat developed soften the material
without reaching to melting point and
enabling the weld .
• Parts have to be securely clamped to prevent
the joint faces from being forced apart .
 CONTINUE
• The plasticized material , transferred to
trailing edge of the tool pin, is forged through
intimate contact with the tool shoulder and
pin profile .
• On cooling a solid phase bond is created
between the work pieces to be welded .
CLAMPING ARRANGEMENT
 TOOLS
• Manufactured tools before and after welding .
 WELDING
• Welding performed on the manual milling machine .
WELDED WORK PIECES
 PROCESS PARAMETERS

Parameters Effect
Rotational speed Frictional heat “stirring” oxide layer breaking and material

Tilting angle The appearance of weld, thinning

Welding speed Appearance , heat control

Down force Frictional heat, maintaining contact condition

 TOOL ROTATION AND TRAVERSE
SPEED
 There are two tool speeds to be considered in
friction stir welding .
 first how fast the tool rotates .
 second how quickly it traverse the interface .
 These two parameters have considerable
importance and must be chosen with care to
ensure the successful and efficient welding
cycle .
 TOOL TILT
• Tilting the tool by 2-4 degrees, such that the
rear of the tool is lower than the front
• That has been found to assist the forging
process .
• It affects the bead characteristics and the
appearance of weld .
 DOWN FORCE/PLUNGE DEPTH
• Plunge depth is defined as the depth of the
lowest point of shoulder below the surface of
the welded plate and has been found critical
parameter for ensuring weld quality .
• The plunge depth needs to be correctly set
both to ensure the necessary downward force
is achieved and to ensure that the tool fully
penetrates the weld .
 TOOL DESIGN
• The design of the tool is critical factors as a
good tool can improve both the quality of
weld and maximum possible welding speed .
• It is desirable that the tool material is
sufficiently strong, tough, and hard wearing at
the welding temperature .
 CHALLENGES TO FSW OF STEEL
• FSW of steel had not been progressing as
rapidly for aluminium and other metals
because of various reasons .
• The material from which the tool is made has
to survive much more strenuous condition
because of strength of steel and high softening
temperature of steel .
 CONTINUE
• The consequences of phase transformations
accompanying FSW has not been studied in
sufficient depth .
• The variety of steel available is much larger
than for any other alloy system, requiring
considerable experiments to optimize the
weld for required set of properties .
• Cost competitiveness .
THE END