26/03/2016

PPT'SFORMECHANICALENGINEERINGSTUDENTS:Frictionstirwelding

PPT'SFORMECHANICAL
ENGINEERINGSTUDENTS
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Raghuramuttej
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Tuesday,20March2012

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Frictionstirwelding

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Frictionstirwelding(FSW)isasolidstatejoiningprocess(meaningthemetalisnotmelted

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duringtheprocess)andisusedforapplicationswheretheoriginalmetalcharacteristicsmust
remainunchangedasfaraspossible.Thisprocessisprimarilyusedonaluminium,andmost
oftenonlargepieceswhichcannotbeeasilyheattreatedpostweldtorecovertemper
characteristics

Principleofoperation
Aconstantlyrotatedcylindrical
shoulderedtoolwithaprofilednibis
traverselyfedataconstantrateintoa
buttjointbetweentwoclampedpieces
ofbuttedmaterial.Thenibisslightly
shorterthanthewelddepthrequired,
withthetoolshoulderridingatopthe
worksurface.
Frictionalheatisgeneratedbetween
thewearresistantweldingcomponents
andtheworkpieces.Thisheat,along
withthatgeneratedbythemechanical
mixingprocessandtheadiabaticheat
withinthematerial,causethestirred
materialstosoftenwithoutmelting.As
thepinismovedforwardaspecial
profileonitsleadingfaceforces
plasticisedmaterialtotherearwhere
clampingforceassistsinaforged
consolidationtheweld.
Thisprocessofthetooltraversing
alongtheweldlineinaplasticised
tubularshaftofmetalresultsinsevere
solidstatedeformationinvolving
dynamicrecrystallizationofthebase
material.

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SchematicdiagramoftheFSWprocess:(A)Twodiscrete
metalworkpiecesbuttedtogether,alongwiththetool(witha
probe).

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(B)Theprogressofthetoolthroughthejoint,also
showingtheweldzoneandtheregionaffectedbythetool
shoulder.

ThesolidstatenatureofFSW
immediatelyleadstoseveraladvantagesoverfusionweldingmethodssinceany
problemsassociatedwithcoolingfromtheliquidphaseareimmediatelyavoided.Issues
suchasporosity,soluteredistribution,solidificationcrackingandliquationcrackingare
notanissueduringFSW.Ingeneral,FSWhasbeenfoundtoproducealow
concentrationofdefectsandisverytoleranttovariationsinparametersandmaterials.
http://uttej55.blogspot.in/2012/03/frictionstirwelding.html

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26/03/2016

PPT'SFORMECHANICALENGINEERINGSTUDENTS:Frictionstirwelding

Nevertheless,FSWisassociatedwithanumberofuniquedefects.Insufficientweld
temperatures,duetolowrotationalspeedsorhightraversespeeds,forexample,mean
thattheweldmaterialisunabletoaccommodatetheextensivedeformationduring
welding.Thismayresultinlong,tunnellikedefectsrunningalongtheweldwhichmay
occuronthesurfaceorsubsurface.Lowtemperaturesmayalsolimittheforgingaction
ofthetoolandsoreducethecontinuityofthebondbetweenthematerialfromeachside
oftheweld.Thelightcontactbetweenthematerialhasgivenrisetothename"kissing
bond".Thisdefectisparticularlyworryingsinceitisverydifficulttodetectusing
nondestructivemethodssuchasXrayorultrasonictesting.Ifthepinisnotlongenough
orthetoolrisesoutoftheplatethentheinterfaceatthebottomoftheweldmaynotbe
disruptedandforgedbythetool,resultinginalackofpenetrationdefect.Thisis
essentiallyanotchinthematerialwhichcanbeapotentsourceoffatiguecracks.

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AnumberofpotentialadvantagesofFSWoverconventionalfusionweldingprocesses
havebeenidentified:[5]
Goodmechanicalpropertiesintheasweldedcondition
Improvedsafetyduetotheabsenceoftoxicfumesorthespatterofmolten
material.
NoconsumablesAthreadedpinmadeofconventionaltoolsteel,e.g.,
hardenedH13,canweldover1kmofaluminium,andnofillerorgasshield
isrequiredforaluminium.
Easilyautomatedonsimplemillingmachineslowersetupcostsandless
training.
Canoperateinallpositions(horizontal,vertical,etc.),asthereisnoweld
pool.
Generallygoodweldappearanceandminimalthicknessunder/over
matching,thusreducingtheneedforexpensivemachiningafterwelding.
Lowenvironmentalimpact.
However,somedisadvantagesoftheprocesshavebeenidentified:
Exitholeleftwhentooliswithdrawn.
Largedownforcesrequiredwithheavydutyclampingnecessarytoholdthe
platestogether.
Lessflexiblethanmanualandarcprocesses(difficultieswiththickness
variationsandnonlinearwelds).
Oftenslowertraverseratethansomefusionweldingtechniques,although
thismaybeoffsetiffewerweldingpassesarerequired.

PostedbyRaghuramuttejat01:01

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