Friction Stir Welding PPT, PDF Report for Mechanical: Abbreviation of friction stir welding is FSW and it was invented by Wayne Thomas at the Welding Institute. Initial patent applications of it were in the United Kingdom in the year of 1991. It is an innovative process of welding and it is also called as a solid state welding process. Friction stir welding is suitable for alloys which have high strength like high strength alloys used in aircraft industry.

Friction Stir Welding PPT, PDF Report

Benefits of friction stir welding:

Friction stir welding has following benefits:

  • Metallurgical benefits
  • Environmental benefits
  • Energy benefits

Benefits related to all the three parameters are explained in below table in a detailed manner.

Metallurgical benefits Environmental benefits Energy benefits
Absence of cracking Saving of consumable materials like wire, rugs and other gases Use of improved materials permits decrease in weight
Solid phase process It eliminates grinding wastes
Fine microstructure Does not need any surface cleaning
Low distortion of workpiece Does not need any shielding gas too Friction stir welding decreases the consumption of fuel in lightweight aircraft automotive and ship applications
No loss of alloying
Good dimensional stability
Repeatability

Table1: Benefits of Friction Stir Welding

A process of FWS:

Working principle of friction stir welding process has a welding tool which is comprised of shoulder, shank, and a pin will be fixed in a milling device chuck which rotates about its longitudinal axis. A workpiece that has square matting edges is fixed to a backing plate which is rigid. There will be a clamp which does not allow workpiece from lifting or spreading during welding. A half plate where the direction of rotation is similar to the direction of rotation of welding is known as advancing side. The other side where the direction of rotation is not similar to the direction of welding is known as a retreating side. After many further steps, we will a final workpiece and all these welds need low input energy, they also don’t use any filler materials and distortion.

Welding variables:

Friction stir welding involves parameters like complex material movement and plastic deformation. Thus the important and independent variables which are used to control process of friction stir welding are mentioned below:

  • Welding speed
  • Tool rotation speed
  • Tool material
  • Tilt angle of tool
  • Tool design

Below table explains about important parameters along with their effects in process of friction stir welding:

Parameters Effects
Downforce Its effects are maintaining contact conditions and frictional heat
Welding speed Heat control and appearance are its effects
Tilting angle This parameter has effects like thinning and appearance of weld
Rotation speed Rotation speed has effects like frictional heat, stirring, breaking of oxide layer and mixing of material

Table2: Important Parameters and their Effects

  1. Tool rotation and transverse speed: For friction stir welding, two important parameters are tool rotation which will be in a clockwise direction or counter clockwise direction and its units are (v, rpm). Tool transverse speed will be along the line of joint and its units are (n, mm/min).
  2. Tool tilt and plunge depth: Including tool rotation and transverse speed, tool tilt, and plunge depth are two other vital parameters of friction stir welding.
  3. Tool design: Tool is a vital part of a friction stir welding process. Tool design influences the below things:
  • Heat generation
  • Required power
  • Plastic flow
  • Uniformity of welded joint

The geometry of tools like probe length, probe shape, and shoulder size acts ac key parameters because they affect plastic material flow and heat generation.

Applications of friction stir welding:

Friction stir welding and its applications in various industries and few of them are mentioned below:

  • Shipping and marine industries
  • Aerospace industries
  • Land transport
  • Railway industries
  1. Shipping and marine industries: In shipping and marine industries t is used in manufacturing of hulls, aluminum extrusions, offshore accommodations and much more.
  2. Aerospace industries: In aerospace industries, it is used in manufacturing of wings, for welding in Al alloy welding tanks which are used in space vehicles, and still there are many applications of it in aerospace industries.
  3. Land transport: In the land transport it is used in body frames, truck bodies, wheel rims, and automotive engine chassis.
  4. Railway industries: In railway industries, it has applications like building of railway tankers and building of container bodies.

Current status and future aspects of FSW:

Current status of friction stir welding: By availing this process, hard materials like steel and other vital engineering alloys can be efficiently welded. It decreases defects and enhances uniformity of weld properties. It also expands applicability of friction stir welding to modern engineering alloys.

Future aspects of friction stir welding: It includes analyzing the influence of processing parameters on welding stages, plunging, and transition. Future work also includes analyses of non-heat treatable aluminum series and heat treatable aluminum. It is a demand of aircraft industries to substitute conventional joining applied sciences with frictional stir welding which is affordable and highly efficient.

Content of the Seminar and PDF Report for Friction Stir Welding

  • Introduction
  • Principles of FSW
  • FSW Set up
  • Materials used
  • Stress –Strain Graph
  • Comparisons
  • Advantages
  • Disadvantages
  • Applications
  • Future Developments
  • Conclusions

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Friction Stir Welding PPT, PDF Report for MechanicalSumit ThakurMechanicalFriction Stir Welding PPT, PDF Report for Mechanical: Abbreviation of friction stir welding is FSW and it was invented by Wayne Thomas at the Welding Institute. Initial patent applications of it were in the United Kingdom in the year of 1991. It is an innovative process of welding and...Seminar Topics