Technical Report and Seminar (TRS)

Presentation

Topic Name : “Friction Stir Welding”

Presented by Guide:
Mr. Amit B Shahare Prof. Vinit Gupta
(Sec A, Roll no. ME18067)
TOPIC -
INTRODUCTION TO ENGINEERING METALLURGY

Date: 24/09/2019 Session: 2019-2020 PRESENTED BY -

PROF. AJAY A. JOSHI

CONTENTS

• INTRODUCTION TO TOPIC
• BLOCK DIAGRAM/ACTUAL DIAGRAM OR FIGURE/VIDEO
• OPERATIONAL FEATURES AND CHARACTERISTICS
• SIGNIFICANCE AND APPLICATIONS IN CURRENT SCENARIO
• COMPARISON WITH OTHER EXISTING TECHNOLOGIES
• ADVANTAGES AND LIMITATIONS
• FUTURE SCOPE
• CONCLUSIONS
INTRODUCTION

 WELDING USING FRICTION AS THE MAJOR RESOURCE

 NO FILLER MATERIAL INVOLVED
 WELDS CREATED BY,

A) FRICTIONAL HEATING
B) MECHANICAL DEFORMATION
DIAGRAM
 HISTORY

 INVENTED BY TWI IN 1991 IN ENGLAND

 28 ORGANIZATIONS WORLDWIDE USE FSW
FRICTION WELDING

 HEAT FROM MECHANICAL ENERGY CONVERSION

• LINEAR FRICTION WELDING

• ROTARY FRICTION WELDING
 FRICTION STIR WELDING

Rotating probe
Sufficient downward force to maintain
pressure and to create friction heat provides friction
heat and
pressure which
Shoulder which creates friction
heat
joins the material
and welding pressure
Sufficient
Probe which Stir the material downward force
to maintain
pressure and to
create 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)
MICROSTRUCTURE ANALYSIS

Optical micrographs of regions (a), (b) and (c) of the stir nugget.
JOINT GEOMETRIES

It can be used in all positions,

Horizontal
Vertical
Overhead
Orbital
MATERIAL SUITABILITY
 COPPER AND ITS ALLOYS
 LEAD
 TITANIUM AND ITS ALLOYS
 MAGNESIUM ALLOYS
 ZINC
 PLASTICS
 MILD STEEL
 STAINLESS STEEL
 NICKEL ALLOYS
WELDING STEEL USING FSW
TOOLS PARAMETERS
COMMON TOOLS

Self Reacting Pin Tool Fixed Pin Tool

Adjustable Pin Tool Retractable Pin Tool

SOME OF THE FSW MACHINES

ESAB SuperStir TM machine FW28

ESAB Machine
APPLICATIONS
• FSW IS MOSTLY USED IN AIRCRAFT INDUSTRIES FOR WELDING WINGS,
FUEL TANKS, AIRCRAFT STRUCTURE ETC.

• USED IN MARINE INDUSTRIES FOR STRUCTURE WORK.

• USED IN AUTOMOTIVE INDUSTRIES TO WELD WHEEL RIMS, CHASSIS,
FUEL TANKS AND OTHER STRUCTURE WORK.

• IT IS USED IN CHEMICAL INDUSTRIES FOR JOINING PIPELINES, HEAT

EXCHANGER, AIR CONDITIONER ETC.

• FRICTION STIR WELDING IS ALSO USED IN ELECTRONIC INDUSTRIES

FOR JOINING BUS BAR, ALUMINUM TO COPPER, CONNECTORS AND
OTHER ELECTRONIC EQUIPMENT’S.

• IT IS WIDELY USED IN FABRICATION INDUSTRIES.

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
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)
COMPARISON WITH OTHER
JOINING PROCESSES
FSW vs Fusion Welding
» Improved Mechanical
Properties
» Reduced Distortion
» Reduced Defect Rate
» Parent Metal Chemistry
» Simplifies Dissimilar Alloy
Welding
» Fewer Process Variables
» Eliminates Consumables
» Reduces Health Hazard
FSW vsRivetting
» Reduced Part Count
» Reduced Production
Time
» Reduced Defect Rates
» Increase in Load
Carrying Capability»
Improved Fracture
Performance
» Eliminates Consumables
» Less Operator
Dependent
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
FUTURE DEVELOPMENTS

 LASER-ASSISTED FRICTION STIR WELDING

 POSSIBLE USE OF INDUCTION COIL AND OTHER MECHANISM
CONCLUSION

 AN ALTERNATIVE TO FUSION WELDING

 ADVANCED TECHNOLOGIES ARE IN THE OFFING
 REFERENCES
Patent(s) Company Priority Date
US 5697544 B Boeing 21.03.1996

US 5713507 B Rockwell 21.03.1996

US 5718366 B Boeing 31.05.1996

JP 3771972 B Showa 30.08.1996

EP 1021270 B; US 6264088 B ESAB 16.05.1997

US 5893507 B NASA 07.08.1997

JP 3045698 B Showa 28.11.1997

US 6199745 B; EP 1105246 A MTS 09.07.1998

US 6247633 B Ford 02.03.1999

EP 1286805 A Norsk Hydro 19.10.1999

EP 1230062 B; US 6722556 B GKSS 18.11.1999

JP 2001259863 A SLM 17.03.2000

US 6497255 B NASA 13.10.2000

JP 3471313 B Kawasaki 13.12.2000

JP 2003305576 A Kawasaki 12.04.2002

US 6758382 B NASA 05.02.2003

US 2005045695 A; EP 1510280 A Boeing 29.08.2003

JP 2005288465 A SLM 31.03.2004

JP 2005319484 A Fuji 10.05.2004

JP 2006000858 A Honda 15.06.2004

US 2006163316 A Boeing 24.01.2005

 REFERENCES

1. SMITH, I. AND LORD,D., "FSW PATENTS - A STIRRING STORY," SAE

TECHNICAL PAPER 2007-01-1707, 2007

2. HTTPS://EN.WIKIPEDIA.ORG/WIKI/FRICTION_STIR_WELDING
3. HTTPS://WWW.YOUTUBE.COM/WATCH?V=BQYLDW8W5WE
4. HTTPS://WWW.YOUTUBE.COM/WATCH?V=ANBQH8XBGXQ
5. HTTPS://WWW.TWI-GLOBAL.COM/TECHNICAL-KNOWLEDGE/FAQS/FAQ-
WHAT-IS-FRICTION-STIR-WELDING
 THANK YOU…

QUERIES AND COMMENTS!