Fric on S r Welding In Manufacturing Process
ABSTRACT:
This paper explores Friction Stir Welding (FSW) is a
revolutionary joining technique in the field of manufacturing, offering
distinct advantages over traditional welding methods. This paper provides
a comprehensive overview of the FSW process, its principles, and its
applications in various manufacturing industries.
The fundamental principles of FSW, including the generation of
heat through friction between a rotating tool and the workpieces, and the
mechanical stirring of the material without melting. This unique
characteristic not only eliminates issues associated with traditional
welding methods, such as solidification defects and thermal distortion but
also broadens the range of materials that can be effectively joined.
Fig 1.1 FSW Welding Optimisation
I. INTRODUCTION:
Welding is the backbone of modern manufacturing,
responsible for joining materials in countless industries. Yet, it is not
without its challenges. The welding process can be a complex,
multifaceted puzzle, where the choice of welding parameters, sequence,
and methods can make or break the quality and cost-effectiveness of the
final product.
In this paper, we present an overview of Friction Stir Welding
techniques where the optimisation or sequence of welding plays a
promising and most widely used technique for minimising the defects as
well as the residual stresses. So, the overview complements the current
literature.
Friction Stir Welding is a solid-state welding process that was
invented by The Welding Institute in 1991. Unlike traditional welding
techniques that involve melting and solidification of the materials being
joined, FSW operates at temperatures below the melting point of the
materials. This characteristic makes it particularly suitable for materials
that are difficult to weld using conventional fusion welding methods.
Fig 1.2 FSW
2.Sustainable manufacturing aspects of FSW
There is an emerging demand for novel welding techniques that are
sustainable, eco-friendlier, and economic, and process efficient. The
aforementioned aspects make FSW a globally accepted green
manufacturing technology . FSW being so-called green technol ogy
is a novel solid-state joining technique consisting of the non
consumable rotating tool with a specially profiled pin that is plunged
into the faying surfaces until the tool shoulder touches the workpiece
surface.
After a specified dwell, the tool is advanced along the joint line at
predetermined process parameters such as welding speed,
rotational speed, tool tilt angle, tool offset, and so ontoaccomplish
the welding process. The heat required for joining is produced by
the combinedeffect of friction between the tool and workpiece pin
and workpiece and by plastic deformation of the workpiece material.
As the tool moves forward along the weld line the pin stir and moves
the plastically deformed material from the leading side to the trailing
side where in combination with the forging action of the tool shoulder
results in a solid-state joint behind the tool pin.
FSW is a novel welding technique bearing worldwide applications
especially in the fabrication of lightweight aluminium structures.FSW
is widely used to join so-called unweldable aluminum alloys such as
alloy series that find a wide range of applications in space shuttles,
automo biles, aircraft wings, and panels. FSW finds extensive
applications in various industries such as aerospace-aircraft,
shipbuilding, loco motives, and automotive industries .
3.Process efficient aspect of FSW
FSW is used to join lightweight materials like alloys of magnesium,
aluminium that are widely used to construct aerospacestructures,
shipbuilding panels, rocket fuel tanks, high-speedtrains, and light
vehicles. For instance, Fjellstrand, a Norwegianshipbuilding
company reported the FSW prefabricated panels usedin
shipbuilding has reduced the production time from 10 monthsto 6
months i.e., 40% increase in production capacity.
US defensecompany; General Dynamics Land System reported that
the FSWprocess has resulted in a reduction of process/cycle time
upto400%, and had enhanced ballistic result tests. Eclipse Aviation
Corporation of Albuquerque, New Mexico has replaced 7000 rivets
andfasteners by FSW process in Eclipse 500 and claimed that in
Eclipse500 the FSW besides eliminating the drilling operation in
rivetinghas resulted in high joining speeds (20 times) as compared
to manual riveting.
Prasad and prassana investigated the microstructure and
microhardness of FSW and GMAW and reported that HAZin GMAW
was wider due to high heat input during the GMAW process. FSW
requires no pre-processing preparation of plates even for50 mm
thick welds. Furthermore, FSW requires no post-
processingoperation due to the absence of filler material that
otherwiserequires grinding or machining and low temperature
experiencedduring the welding process leading to low thermal
distortion.
The low distortion incorporated in FSW has led to the fabrication of
modern car bodies of the train such as Hitachi in 2000
where FSW has resulted in cost-effective fabrication of high
integrity, and high-speed train car bodies.
4. Applica on
Aerospace Industry: FSW is widely used in the aerospace industry
for joining aluminum and other lightweight materials. It is used in the
fabrication of aircraft components, such as wing panels, fuselage
sections, and engine parts, where high strength and low weight are
crucial.
Automotive Industry: FSW is utilized for manufacturing automotive
components, especially in electric vehicles (EVs) where lightweight
materials like aluminum are commonly used for battery enclosures,
body structures, and heat exchangers.
Shipbuilding and Maritime Industry: FSW is used to join aluminum
and other non-ferrous materials in ship and boat manufacturing. It
offers improved corrosion resistance and reduced distortion
compared to traditional welding methods.
Railway Industry: FSW is employed in the construction of railway
components, including train carriages, aluminum doors, and
lightweight structures. Construction and Infrastructure: FSW is used
for architectural and structural components, including bridges,
aluminum framework, and other lightweight structures in
construction.
Oil and Gas Industry: FSW is applied in the manufacture of
pipelines, as it can join thick-walled pipes made of materials like
stainless steel and other non-ferrous metals with reduced heat-
affected zones.
Space Exploration: For space exploration and the construction of
spacecraft, FSW is used to create joints with high structural integrity
and minimal weight. Electronics and Heat Exchangers: FSW can
be used for creating heat sinks and other electronic components that
require effective heat dissipation without damaging sensitive
electronic elements.
Renewable Energy: FSW is employed in the manufacturing of
components for renewable energy systems such as wind turbines,
solar panels, and hydroelectric systems.
5.Limitations of FSW
Besides the potential advantages of FSW, there are various
limitations in its real applications .For instance, FSW is not a suitable
welding technique to join high melting point alloys/materials.
Joining higher melting point materials by FSW requires costlier tool
materials that can withstand higher operat ing temperatures and
should possess high hot hardness. Also, the joining of unequal
thickness similar/dissimilar materials of higher thickness ratio’s by
the FSW process results in joints with lower weld quality.
The FSW process ends with an exit hole that leads to the wastage
of a significant amount of material/re sources. Unlike FW, the
FSWed joints are associated with various joint defects such as
tunneling defects, kissing bond defects, JLR defects, void defects,
hooking defects, and excess flash that dete riorate the joint
properties.
Defect formation in FSW is caused by an improper combination of
process parameters leading to insuf f icient heat generation,
inadequate material mixing, and incom plete material consolidation
behind the pin.
Moreover, FSW requires complex fixture requirements for holding
the base materials during the welding process. Besides, FSW is less
flexi ble as compared to the conventional FW process and is not cap
able of joining in complex joint configurations.
In addition to this, the FSW process involves a higher initial cost as
compared to the FW process. However, the FSW process can be
made more reliable by hybridizing the FSW process with other
joining tech niques, by automation and robotization of FSW to make
it more process efficient and economic for welding high strength
materials.
Table shows the defects of welding
CONCLUSION
This study provides us the sequencing of welding optimisation and other
techniques. However, the main difference of this paper is that it is focused
on sustainable manufacturing aims at the reduction or eliminationof
harmful gases, wastes, and optimum utilization of naturalresources with
energy-efficient processing involving minimumimpact on the
environment.Sustainable welding aims at maximizing process
efficiency,minimizing environmental impact, maximizing energy efficiency,
optimizing resource utilization, and minimizingwastage of resources.FW
being a flexible joining process but involves the use of fillermaterials,
fluxes, electrode coatings (as flux), and shieldinggases leading to
generations of fumes, emission of harmfulgases, and radiations to the
environment.
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