DEVELOPMENT OF FRICTION STIR

WELDING SET UP FOR TITANIUM ALLOY

Batch No: 22

Franston Chris Dsouza Guruprasad Likith T Naik Mohammed Shihad

4NM20ME026 4NM20ME030 4NM20ME043 4NM20ME052

Guide: Mr. Rajath N. RAO

Dept of Mech. Engg. NMAMIT Nitte
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 Flow of the Presentation
1. Introduction
2. Literature Review
3. Objectives
4. Methodology
5. Experimental setup
6. Tool specification
7. Conclusion

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Dept. of Mechanical Eng. NMAMIT
 1. Introduction
• Friction stir welding is a non-consumable solid-state joining technique that
enables the joining of two facing workpieces without melting the material.
• Frictional heat is generated between the wear-resistant tool and the work
pieces.
• FSW is a welding technique where a spinning tool with a specially designed
pin and shoulder is inserted into the intended work-pieces.
Fig 1. Friction stir welding
• The strength of FSW weld is reported to be 30% - 50% higher than that of
arc welding and resistance spot welding.
• Parameters that will be used are tool rotation speed , welding speed and
tilt angle.
• Titanium is 45% lighter than steel and 60% heavier than aluminium, yet it
has strength nearly three times that of either alloy.
• Titanium has The Highest Strength to weight Ratio.
Fig 2. Friction stir texture
• Titanium alloy is known for its high strength, stiffness, toughness, low
density, and excellent corrosion resistance.Dept. of Mechanical Eng. NMAMIT
04/01/2024 3
 2. Literature Review
Name of the
Year Journal/ Paper/others Details & Summary
author
Jia-Wei Bao 2018 Microstructural evolution, Discusses the microstructural evolution, tensile
tensile property and dynamic property, and dynamic compressive property of
Su-Yuan Yang compressive property of FSWed Ti–6Al–4V alloy. The study investigates the
FSWed Ti–6Al–4V alloy. effects of friction stir welding on the microstructure
Ting Yang and mechanical properties of Ti–6Al–4V plates. The
results show promising improvements in
compressive strength and failure strain, as well as
larger energy absorption compared to the base
material.
Amit Kumar Singh 2019 Friction stir welding of In this study difficulties arise while printing complex
additively manufactured Ti- and huge structures and therefore, the components
Bhoopendra Kumar 6Al-4V: Microstructure need a suitable joining process. They study the
and mechanical properties. feasibility of friction stir welding of Ti-6Al-4 V plates
Kaushal Jha
made by electron beam melting, performing both
microstructural and mechanical analysis.

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Dept. of Mechanical Eng. NMAMIT
 Name of the
author Year Journal/ Paper/others Details & Summary
Junping Li 2020 Friction stir welding of Ti-6Al- A newly designed friction tool was used to join Ti-
4V alloy: Friction tool, 6Al-4V alloy plates with a thickness of 2 mm. The
Yifu Shen Wentao microstructure, and microstructure and mechanical properties of the
Hou mechanical properties. welds were investigated. The results showed that
defect-free welds could be produced under
Yiming Qi optimized process parameters.
H.J. Liu 2010 Microstructural characteristics Friction stir welding (FSW) was applied to Ti–6Al–4V
and mechanical properties of titanium alloy sheets with a thickness of 3 mm. The
L. Zhou friction stir microstructures and mechanical properties of the
welded joints of Ti–6Al–4V joints were investigated. The tensile strength of the
Q.W. Liu titanium alloy joints was higher than that of the BM (Base
Material), and the elongation was slightly lower
than that of the BM. The fracture occurred in the
BM during the tensile test

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Dept. of Mechanical Eng. NMAMIT
 Name of the
author Year Journal/ Paper/others Details & Summary
Shude Jia, 2017 Eliminating the tearing In the 2017 paper by Shude Ji et al., a new approach
Zhengwei Lib, defect in Ti-6Al-4V alloy called back heating assisted friction stir welding
Liguo Zhanga , joint by back heating (BHAFSW) is proposed to address tearing defects in
Yue Wang assisted friction stir welding Ti-6Al-4V alloy joints. By reducing temperature
gradients and improving material flow behavior,
defect-free joints with enhanced properties are
obtained. The BHAFSW method not only eliminates
tearing defects but also reduces tool wear during
welding, offering a promising solution for improving
joint quality and efficiency

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 3. Objectives

 To designing of resistance heating setup for conventional milling machine

 To perform Friction stir welding of preheated titanium alloy

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Dept. of Mechanical Eng. NMAMIT
 4. Methodology
 Preparation of the titanium plate to the required dimensions
 Selection of the tool material and tool pin profile for friction stir welding of titanium
 To prepare suitable FSW set up for the conventional milling machine including the resistance
heating coils
 Selection of proper welding parameters which was opted from the literature review

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Dept. of Mechanical Eng. NMAMIT
 5.DESIGNS

Fig 3. Experiment set up Fig 4. Baseplate with coil

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 6.Experimental setup
Argon gas
FSW Machine

Heating device Base plate

Vice
Heat
measuring
device

04/01/2024 Fig 5. Experimental Setup 10

 Fig 6. Fireproof blanket
Fig 7. Acrylic box

• Made of flame-resistant fabric like fiberglass,
silica, or ceramic fiber, providing insulation and
protection against heat.
• Several millimetres thick and can withstand
high temperatures.
• They contain heat within the welding area, are
durable, and provide complete coverage.
• The enclosure is made of acrylic (PMMA),
typically 5mm-10mm thick.
• Clear or transparent, allowing visual monitoring
of the welding process.
• It has better heat resisting capacity.

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 Fig 8. Vice
• Is made up of mild steel ,for heavy duty
applications such as FSW where strength
and stability is preferred.
• It is tightened on the bed using a pair of
bolts.
• The vice used here has length of 200mm ,
breadth 145mm , thickness of 26mm and
inner thickness of the slot is 15mm.
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Fig 9. Baseplate
• Base plate is mounted on the vice with a
heating coil inserted in it , with the help of
the base plate the alloy is being heated.
• This base plate is made up of Mild steel
due to its ease of machining, and
moderate strength.
• MS plate here has a length of 150mm ,
breadth of 100mm and thickness of
16mm. 12
 Fig 10. Resistance heating coil
• It is a crucial component used in friction stir
welding setup.
• Made from high-resistance alloys like nichrome
• Capable of withstanding high temperatures,
often exceeding 1000°C.
• Device is used to convert electrical energy into
heat for even heating of the base plate.
• Heating power can be controlled by adjusting
electrical current on the device.
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Fig 11 . Glass wool
• Glass wool is a versatile insulating material
used for thermal insulation.
• Its fibrous structure reduces heat transfer,
has low thermal conductivity, and is fire-
resistant.
• Its lightweight and flexible nature makes it
easy to install and manipulate. Glass wool
also provides acoustic insulation.
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 Fig 11. Rubber mat
• A rubber mat is used below an acrylic setup to
reduce heat transfer
• It acts as a thermal insulator, reducing heat
transfer from the heated base plate and vice to
the surrounding surfaces.
• This helps maintain a stable temperature and
protects underlying surfaces from damage.
• Its flexibility allows for easy installation and
removal, and can be customized to fit specific
workspace
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dimensions.
Fig 12. Insulation tape
• A highly flexible material, with the
adhesive tape, resistant to atmospheric
agents
• Resistance to humidity and chemical
agents, thermal conductivity, resistance
to high temperatures and the ability to
diffuse and reflect light.
• Eliminate air leaks in air conditioning
and ducting systems.
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 7. Tool specification

Fig 13 . Tungsten tool

• Tungsten carbide tool with a 20 mm shoulder diameter, probe length of
2.6 mm with a diameter of 7 mm and 4 mm at the pin root and tip,
respectively was used for joining.

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 8.Experiments Conducted
Experiment 1 - Inadequate preheating of baseplate

Fig 14.Excess heat of plate Fig 15. Broken tool Fig 16. FSW setup
• Inadequate preheating of baseplate led to experiment failure
• Tool breakage occurred upon initial contact with Ti6Al4V workpiece
• Preheating is crucial for stress alleviation and uniform heating
• Importance of adhering to precise preheating protocols

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Experiment 2 - Excess Preheating

• Overheating of Ti6Al4V workpiece due to inaccurate temperature readings

• Resulted in transparent hole formation and material hardening around tool tip
• Underlines the importance of precise temperature control in friction stir welding
• Emphasize the need for reliable temperature monitoring for future success

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Experiment 3 - Enhancing Stability with Bolt Redesign

• Instability during experiment due to star head bolts used in vice

• Resulted in excessive vibrations and tool breakage
• Addressed issue by fabricating new bolts with square heads
• Improved stability and torque transmission
• Emphasize proactive approach to component design for future success

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 9. Conclusions

• Suitable set up has been done for stir welding machining of Titanium
alloy
• Faced failures in experiments conducted due to excess heat, under
heat, and instability of vice.
• Further experiment will proceed in next phase

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Dept. of Mechanical Eng. NMAMIT
 Reference

Bao, J., Yang, S., & Yang, T. (2018). Microstructural evolution, tensile property and dynamic compressive property of FSWed Ti–6Al–4V
alloy. Rare Metals, 39(2), 169–175. https://doi.org/10.1007/s12598-018-1151-6

Singh, A. K., Kumar, B. P., Jha, K., Astarita, A., Squillace, A., Franchitti, S., & Arora, A. (2020). Friction stir welding of additively
manufactured Ti-6Al-4V: Microstructure and mechanical properties. Journal of Materials Processing Technology, 277, 116433.
https://doi.org/10.1016/j.jmatprotec.2019.116433

Li, J., Shen, Y., Hou, W., & Qi, Y. (2020). Friction stir welding of Ti-6Al-4V alloy: Friction tool, microstructure, and mechanical
properties. Journal of Manufacturing Processes, 58, 344–354. https://doi.org/10.1016/j.jmapro.2020.08.025

Liu, H., Zhou, L., & Liu, Q. (2010). Microstructural characteristics and mechanical properties of friction stir welded joints of Ti–6Al–4V
titanium alloy. Materials in Engineering, 31(3), 1650–1655. https://doi.org/10.1016/j.matdes.2009.08.025

Ji, S., Li, Z., Zhang, L., & Wang, Y. (2017). Eliminating the tearing defect in Ti-6Al-4V alloy joint by back heating assisted friction stir
welding. Materials Letters, 188, 21–24. https://doi.org/10.1016/j.matlet.2016.10.032

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 Thank You.

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Dept. of Mechanical Eng. NMAMIT