FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN

UNIVERSITI TEKNIKAL MALAYSIA
MELAKA

JOINING TECHNOLOGY
BMMP 3523 REV :01

LAB 1: FRICTION STIR WELDING

1.
NAMES OF GROUP
MEMBERS & 2.
MATRIX NUMBER
3.

4.

5.

COURSE

NAME OF 1.
INSTRUCTOR
2.

EXAMINER’S COMMENT VERIFICATION

STAMP

TOTAL MARKS :
REV NO DESCRIPTION DATE OF REVISON
01 Contents reviewed after 5 years 30/8/2018
02
03
04
 FRICTION STIR WELDING

1.1 OBJECTIVES

The objectives of this laboratory are;

1. Perform the Friction Stir Welding in order to welding butt joint of aluminium plates.

2. Investigate the effect of welding parameters such as arc current, voltage, travel speed and
feed rate on the welding conditions and strength.

3. Analyze the welding parameters against tensile strengths of the weld.

1.2 INTRODUCTION

Friction stir welding (FSW) is a solid state joining process that uses a non-consumable
tool to join two facing workpieces without melting the workpiece material. Heat is generated
by friction between the rotating tool and the workpiece material, which leads to a softened
region near the FSW tool. While the tool is traversed along the joint line, it mechanically
intermixes the two pieces of metal, and forges the hot and softened metal by the mechanical
pressure, which is applied by the tool, much like joining clay, or dough. It is primarily used on
wrought or extruded aluminum and particularly for structures which need very high weld
strength.

A rotating cylindrical tool with a profiled probe is fed into a butt joint between two
clamped workpieces, until the shoulder, which has a larger diameter than the pin, touches the
surface of the workpieces. The probe is slightly shorter than the weld depth required, with the
tool shoulder riding atop the work surface. After a short dwell time, the tool is moved forward
along the joint line at the pre-set welding speed.

This process of the tool traversing along the weld line in a plasticized tubular shaft of
metal results in severe solid state deformation involving dynamic recrystallization of the base
material. FSW is a process which produces welds of high quality in difficult to weld materials
such as aluminum, and is fast becoming the process of choice for manufacturing lightweight
transport structures such as boats, trains and aero planes.
 Figure 1: Schematic illustration of the Friction Stir welding process

1.3 SETUP

1. Friction Stir Welding machine (Model : FSW2-100)

2. Aluminium plates sizes (25mm X 120mm X 2mm) X 2 pieces

1.4 EXPERIMENTAL PROCEDURE

1. Each group should consist of 4 or 5 person.

2. Each group is given a raw material of 2 mild steel plates with size of 25mm X
120mm X 2mm.

3. By referring to the machine operation manual, identify the suitable

welding parameters that can affect the mild steel weld.

4. Fill in the selected process parameters together with their values in Table 1.

5. Perform butt joint of the mild steel plates using the selected parameter
and variables.

6. Observe for defects on the weld if any and record the result.

7. Measure the width of the weld using a Vernier Calliper and record the result in
Table 1.
1.5 SAMPLE PREPARATION FOR TENSILE TESTING
After the samples have been welded, it needs to cut off using Hand Notcer
Machine and the size of each specimen is equally divided into 7 pieces. 5 pieces
from one completed weld plate were taken for tensile testing as shown in Figure 2.
The start and stop points were cut off, is not included in the evaluation.

Figure 2: Specimen cutting for Hand Notcher Machine

1.6 TENSILE TEST

1. Locate the welded plate in the midway between the jaws of the testing machine.
2. The width thickness of the test specimen is measured before testing, and the area in
square inches is calculated by multiplying these before testing.
3. The tensile test specimen is then mounted in a machine that will exert enough pull
on the piece to break the specimen.
4. The specimen is being tested in this machine; the load in pounds is registered on the
gauge.
5. In the stationary types, the load applied may be registered on a balancing beam. In
either case, the load at the point of breaking is recorded.
6. Record result of Yield Strength and Tensile Strength in Table 2 below.
 Figure 3 : Tensile test

1.7 RESULT AND DISCUSSION

Complete the following data/table 1.

Size of Tool (mm):

Table 1: The effect of selected parameter and variables on the width of the weldment
WELDING PARAMETERS
NO. OF EXPERIMENT
Remarks (for defects,
WIDTH (MM)
if any)

Table 2: Mechanical properties of welded material

SPECIMENT NO. Yield Strength(Mpa) Tensile Strength (Mpa)
1.8 SAFETY PROCEDURES

1) Always keep safety in mind.

2) Wear eye protection and safety shoes at all times.
3) Do not wear neckties, wristwatches, rings jewellery, etc. when operating the
machine. Long sleeve shirts will be rolled above the elbows.
4) The area surround the machine should be free of oil or coolant spills (avoid a
slippery floor) and as free as possible from obstruction. Keep the area clean at all
times.