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By Ummen Sabu
13ETMMO8
M.Tech Materials Engineering
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WHAT IS FRICTION STIR WELDING
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THEORY OF FSW
Friction Stir Welding transforms the metals from a solid state into a plastic state
( For Al a temperature of 350-450 ℃ is required )
The tool mechanically stirs the materials together under pressure to form a
welded joint.
FSW uses a rotating, non consumable tool moved along the length of the joint.
The rotation of the tool heats up and plasticizes the materials in contact with tool
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FRICTION STIR WELDING PROCESS
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TOOL USED
FSW tools must be made out of material that is significantly harder and stronger than
the material to be joined to maintain rigidity
shoulder
Ds
H probe
Dp
COMMONLY USED TOOL MATERIALS
High speed steel
EN Steel
PCBN
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EFFECT OF ROTATIONAL SPEED ON WELD QUALTY
An optimum range of rotational speed exists for better quality of the weld
(For commercial aluminium 1200-1400 RPM is the range)
If the speed is lower than this value the friction heat produced is less sufficient
and quality of weld decreases
If the speed is higher than the optimum range excessive heat produced results
in cracking and quality of weld decreases
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DIFFICULTIES OF WELDING ALUMINIUM BY FUSION PROCESS
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Aluminium reacts with oxygen in the air to produce a thin film of Aluminium
oxide on the surface
Aluminium oxide melts at about 2050oC, which is almost three times the melting
point of pure Aluminium, 660oC
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Aluminium welds decrease about 6% in volume when solidifying from the
molten state on cooling
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MICRO STRUCTURE FEATURES
A. Unaffected material
B. Heat affected zone (HAZ)
C. Thermo-mechanically affected zone (TMAZ)
D. stir zone (Part of thermo-mechanically affected zone)
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The friction stir welded joints possess four mutually distinct microstructural regions.
UNAFFECTED ZONE
Region starting from outside towards the center of the weld, this region is the un-
affected zone i.e. the base metal.
A very little microstructural changes occur in the HAZ due to the heat of welding
STIR ZONE
The weld region that has direct interaction with the tool probe
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Microstructural Variation of 6061 Al Alloy Joints by Friction Stir Welding
Won-Bae Lee, Yun-Mo Yeon and Seung-Boo Jung
Department of Advanced Materials Engineering,Sungkyunkwan, Korea
Materials Transactions, Vol. 45,No.5pp. 1700 to 1705 The Japan Institute of Metals 15
ADVANTAGES
Does not create hazards such as welding fumes, radiation, high voltage,
liquid metals, or arcing
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DIS-ADVANTAGES
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APPLICATIONS OF FSW
Aerospace applications
Personal computers
Apple applied friction stir welding on the 2012 iMac to effectively join
the bottom to the back of the device.
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MAIN FSW MACHINES IN INDIA
2. BHEL, Thiruchirapally
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NEED FOR INDIGENOUSLY DEVELOPED FSW AND
OTHER MACHINERIES
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CONCLUSION
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REFERENCES
[3] http://www.twi.co.uk/technical-knowledge/published-papers/friction-stir-
welding-of-aluminium-alloys/
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Thank you