SEMINAR

ON
FRICTION STIR WELDING

GUIDED BY: PROF. AASHISH MOGREKAR

SEAT NO: T120910893
PRESENTED BY: MR.SURAJ TIRUKE

D.Y.P.I.E.T
 Introduction
In late 1991 a very novel and potentially world beating welding method was conceived at TWI.

The process was duly named friction stir welding (FSW), and TWI filed for world-wide patent protection in December of that year.

TWI (The Welding Institute) is a world famous institute in the UK that specializes in materials joining technology. Consistent with the more conventional
methods of friction welding, which have been practiced since the early 1950s, the weld is made in the solid phase, that is, no melting is involved.

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Compared to conventional friction welding, FSW uses a rotating
tool to generate the necessary heatfor theprocess.

Since its invention,the processhas received world-wide

attention and today two Scandinavian companies are using the
technology in production, particularly for joining aluminium
alloys.

Also, FSW is a process that can be automated. It is also a

cleaner and more efficient process compared to conventional
techniques

D.Y.P.I.E.T
History
Invented by TWI in 1991 in England
28 organizations worldwide use FSW

D.Y.P.I.E.T
Friction Welding
Heat from mechanical energy conversion

Linear friction welding

Rotary friction welding

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 Friction Stir Welding
Rotating
Sufficient downward force to maintain
pressure and to create friction heat probe
provides
friction heat
Shoulder which creates friction
heat
and pressure
and welding pressure
which joins
Probe which Stir the material the material
Sufficient
downward
force to
maintain
pressure and
to create
D.Y.P.I.E.T friction heat
Microstructure
Analysis

A. Unaffected material
B. Heat affected zone (HAZ)
C. Thermo-mechanically affected zone (TMAZ)
D. Weld nugget (Part of thermo-mechanically
affected zone)

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Microstructure
analysis

Optical micrographs of regions (a), (b) and (c) of

the stir nugget.

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Joint Geometries

It can be used in all positions,

Horizontal
Vertical
Overhead
Orbital

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Material Suitability
Copper and its alloys
Lead
Titanium and its alloys
Magnesium alloys
Zinc
Plastics
Mild steel
Stainless steel
Nickel alloys

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Welding Steel using
FSW

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Tools Parameters

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Common Tools

Self Reacting Pin Tool Fixed Pin Tool

Adjustable Pin Tool Retractable Pin Tool

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Some of the FSW
Machines

ESAB SuperStir TM
ESAB Machine
machine FW28

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Advantages
Diverse materials: Welds a wide range of alloys, including
previously un-weldable (and possibly composite materials)

Durable joints: Provides twice the fatigue resistance of fusion

welds.

Versatile welds: Welds in all positions and creates straight or

complex-shape welds

Retained material properties: Minimizes material distortion

Safe operation: Does not create hazards such as welding fumes,

radiation, high voltage, liquid metals, or arcing

No keyholes: Pin is retracted automatically at end of weld

Tapered-thickness weld joints: Pin maintains full penetration

D.Y.P.I.E.T
Aerospace industry

At present the aerospace industry is welding prototype parts by friction

stir welding .Opportunities exist to weld skins to spars, ribs, and
stringers for use in military and civilian aircraft. This offers significant
advantages compared to riveting and machining from solid, such as
reduced manufacturing costs and weight savings. Longitudinal butt
welds and circumferential lap welds of Al alloy fuel tanks for space
vehicles have been friction stir welded and successfully tested. The
process could also be used to increase the size of commercially
available sheets by welding them before forming. The friction stir
welding process can therefore be considered for:

Wings, fuselages, empennages

Cryogenic fuel tanks for space vehicles

Aviation fuel tanks

External throw away tanks for military aircraft

Military and scientific rockets

Repair of faulty MIG welds D.Y.P.I.E.T

Comparison with other joining
processes
Reduced Part
FSW
FSW vs Fusion Welding Count
Improved Mechanical vsRivetting
Reduced
Properties Production Time
Reduced Distortion Reduced Defect
Reduced Defect Rate Rates
Parent Metal Increase in Load
Chemistry Carrying
Simplifies Dissimilar Capability
Alloy Welding Improved Fracture
Fewer Process Performance
Variables Eliminates
Eliminates Consumables
Consumables Less Operator
Reduces Health Dependent
Hazard

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Disadvantages
Work pieces must be rigidly clamped

Backing bar required (except where self-reacting

tool or directly opposed tools are used)

Keyhole at the end of each weld

Cannot make joints which required metal

deposition (e.g. fillet welds)

D.Y.P.I.E.T
Barriers for FSW
Special clamping system necessary
Only for simple joint geometries (e.g. butt
joint)
License required from TWI
Few applications in the construction industry
Corrosion protection is needed

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Future Developments
Laser-assisted friction stir welding
Possible use of induction coil and other
mechanism

D.Y.P.I.E.T
Conclusion
An alternative to fusion welding
Advanced technologies are in the offing

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THANK
YOU

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