FRICTION

STIR
WELDING
PREPARED BY:- Atul Chauhan
INTRODUCTION
Welding is a process of joining of different or similar material
through the use of heat and sometimes the addition of other metals
or gases, causes the metallic structures of the two pieces to join
together and become one.
Advantages
 Economical
 Considerable freedom in designing
 Large no. of dissimilar or similar materials joined
 Weld as strong as the parent metal
 CLASSIFICATION OF
WELDING
Mainly welding is classified into two categories.
They are:
a) Fusion welding :
* heated to molten state
* no pressure required
* Example: Gas welding, Arc welding
b) Plastic welding:
*heated to plastic state
*pressure required
*Example: friction welding,
forge welding
Basic Principle of FRICTION STIR WELDING
 Friction is the force resisting the relative motion of solid
surfaces, fluid layers, and material elements sliding against
each other.

 Welding using friction as the major resource is called

friction stir welding.

Welds are created by,

a) Frictional heating
b) Mechanical deformation
FRICTION STIR WELDING
An Overview
 Friction stir welding (FSW) was invented at The Welding Institute
(TWI) of UK in 1991 as a solid-state joining technique, and it was
initially applied to aluminum alloys.
 In FSW, A non-consumable rotating tool with a specially designed
pin and shoulder is inserted into the abutting edges of sheets or
plates to be joined and traversed along the line of joint .
 The tool serves two primary functions:
(a) heating of workpiece, and
(b) movement of material to produce the joint
Friction Stir Welding Tool Material

shoulder
Pin/Probe
 Tool material :- High carbon steel .
 Reasons :- 1) It retains its properties at
elevated temperature
2) Good machinability.
3) Less wear.
4) Have long life.
Schematic Diagrams of FSW Tool:
WORKING PRINCIPLE OF FSW

Parameter Effects

Rotation speed Frictional heat,

stirring

Welding speed Appearance, heat

control

Down force Frictional heat,

maintaining
contact
conditions.
Schematic diagram of the FSW process
(contd.)
 Micro-Structural features
THE SOLID-STATE NATURE OF THE FSW PROCESS, COMBINED WITH ITS UNUSUAL TOOL
SHAPE AND ASYMMETRIC SPEED PROFILE, RESULTS IN A HIGHLY CHARACTERISTIC
MICRO-STRUCTURE. THE MICRO-STRUCTURE CAN BE BROKEN UP INTO THE FOLLOWING
ZONES:

 THE STIR ZONE

 THE FLOW ARM ZONE

 THE THERMO-MECHANICALLY AFFECTED ZONE (TMAZ)

 THE HEAT-AFFECTED ZONE (HAZ)

 Welding Variables
 THE WELDING SPEED, TOOL ROTATIONAL SPEED, THE VERTICAL
PRESSURE ON THE TOOL, THE TILT ANGLE OF THE TOOL AND THE TOOL
DESIGN ARE THE MAIN INDEPENDENT VARIABLES THAT ARE USED TO
CONTROL THE FSW PROCESS.
 THE HEAT GENERATION RATE, TEMPERATURE FIELD, COOLING RATE, X-
DIRECTION FORCE, TORQUE, AND THE POWER DEPEND ON THESE
VARIABLES.
 THE PEAK TEMPERATURE INCREASES WITH INCREASING ROTATIONAL
SPEED AND DECREASES SLIGHTLY WITH WELDING SPEED.
 THE TORQUE DECREASES WITH INCREASE IN THE TOOL ROTATION SPEED
DUE TO INCREASE IN THE HEAT GENERATION RATE AND TEMPERATURE
WHEN OTHER VARIABLES ARE KEPT CONSTANT.
 HIGH TRAVERSE SPEEDS TEND TO REDUCE HEAT INPUT AND
TEMPERATURES.
Materials
Friction stir welding can be used for joining-
Aluminum.

Copper and its alloys.

Zinc, plastic, and nickel alloys.

Applications of friction stir welding
 Ship building and marine industries.
 Robotics
 Aerospace & Automotive industry.
 General fabrication.
 Railways.
 `
Metallurgical benefits Environmental benefits Energy benefits

1)Solid phase process 1) No shielding gas 1) Improved materials use

2)Low distortion of work required (e.g., joining different
piece 2) No surface cleaning thickness) allows reduction in
3) Good dimensional required weight
stability and 3) Eliminate grinding wastes 2) Decreased fuel
repeatability 4) Consumable materials consumption in light weight
4) No loss of alloying saving, such as rugs, wire or aircraft automotive and ship
elements any other gases applications
5) Fine microstructure
6) Absence of cracking
 Work pieces must be rigidly clamped
 Less flexible than manual and arc
processes
 Key holes at the end of each weld
 Backing plate is required
It can only be applied to materials with
low strength and low melting point.
Conclusion
✓ New technology with vital application in
aerospace and marine
✓ Presently limited to aluminum ,its alloys and
related metals
✓ FSW of steel and titanium alloys are
developed and they are in the nascent stage
✓ Will emerge as a better welding technology
Thank You