ADVANCED
MANUFACTURING PROCESS
FRICTION STIR WELDING
- A GREEN TECHNOLOGY
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MECHANICAL ENGG.
RAGHU INSTITUTE OF TECHNOLOGY
FRICTION STIR WELDING
Friction stir welding (FSW) is a
modification of the traditional
friction welding. It is a mechanical
process whereby solid-state welding
is performed using heat generated
from the friction of a rotating tool.
This process is invented and
patented by The Welding Institute
(TWI) in the United Kingdom in
1991 for butt and lap welding of
metals and plastics.
(FSW) can be considered
as a “greentechnology”
because no gases are
evolved during the
process.
Also, there are no toxic
fumes or smoke produced
during or after the
welding process. The
process is energy
efficient and
environmentally friendly.
Compared to other
conventional fusion
welding methods, FSW
offers a number of
advantages.
Comparison with other joining
processes
FSW v/s Fusion FSW v/s Riveting
Welding
» Improved » Reduced Part Count
Mechanical Properties
» Reduced Production
» Reduced Distortion Time
» Reduced Defect Rate » Reduced Defect
Rates
» Parent Metal » Increase in Load
Chemistry Carrying Capability
» Simplifies Dissimilar » Improved Fracture
Alloy Welding Performance
» Fewer Process » Eliminates
Variables Consumables
» Eliminates
Mechanism:
The process involves plunging a non-consumable tool
between the abutting edges of the two plates to be butt
welded,
traversing the tool along the joint line (at a
predetermined rotational speed and feed rate), and at the end,
the tool is retracted from the weld. The fundamental
difference between conventional welding techniques and the
solid-state Friction Stir Welding (FSW) technique is that no
heat is added to the ‘system’; instead heat is generated
internally by means of friction between the tool-material
interface resulting in the plastic deformation of the material
around the stir zone.
Conventional diagram of tool bit and
working material:
Tool bits used in FSW:
Traditional tool bit Tool bits for other materials
Components:
Tool Profile:
STRESS ANALYSIS :
The tool pin, the weakest component of the tool,
experiences severe stresses at high temperatures due to
both bending moment and torsion. It is shown that the
optimum tool pin geometry can be determined from its
load bearing capacity for a given set of welding variables
and tool and work-piece materials. The traverse force and
torque during friction stir welding are computed using a
three-dimensional heat transfer and viscoplastic material
flow model considering temperature and strain rate-
dependent flow stress of the work-piece material. These
computed values are used to determine the maximum
shear stress experienced by the tool pin due to bending
moment and torsion for various welding variables and tool
pin dimensions. It is shown that a tool pin with smaller
length and larger diameter will be able to sustain more
stress than a longer pin with smaller diameter. The
proposed methodology is used to explain the failure and
deformation of the tool is contributed by low values of
Tool Material used according to the Welded Material :
Alloys to be welded Thickness (mm) Tool material
Aluminium alloys 3 – 50 Tool steels, Co-WC
composite
Magnesium alloys 3 – 10 Tool steel, WC composite
Copper alloys 3 – 50 Ni-alloys, W-alloys, PCBN,
Tool steels
Titanium alloys 3 – 10 W-alloys
Stainless steels 3 – 10 PCBN, W-alloys
Low-alloy steels 3 – 10 WC composite, PCBN
Nickel alloys 3 - 10 PCBN
Size of Material that can be welded :
Currently the sizes of the clamping arrangements determine the size of
welded structure and, although length of plate is no longer a problem, the
plate being passed between the clamps after welding to allow location and
clamping of the next section, the actual width of the clamps must be of a
finite size so there is a restriction in the maximum width of plate
Producible.
Example : Perhaps the whole plate for a ship’s hull can be produced in one
piece and then fabricated to shape.
Material Flow:
Rotating probe provides friction
heat and pressure which joins
the material. Sufficient
downward force is provided to
maintain
pressure and to create friction
heat. Frictional heat between
the wear resistant welding tool
and the work pieces causes the
latter to soften without reaching
melting point, allowing the tool
to travel along the weld line.
The plasticised material,
transferred to the trailing edge
of the tool pin, is forged through
intimate contact with the tool
shoulder and pin profile.
Microstructure:
A. Unaffected material
B. Heat affected zone (HAZ)
C. Thermo-mechanically affected zone (TMAZ)
D. Weld nugget (Part of thermo-mechanically
affected zone)
Types of joints:
It can be used in all
positions,
Horizontal
Vertical
Overhead
Orbital
Figure shows Orbital type of weld.
Friction Stir Welding Machine
Application areas:
FSW is widely used in
the following industries,
• Aero space
• Civil Aviation
• Automotive
• Ship building
• Floor panels for bullet trains
• Inserts for nuclear fuel
Preliminary trails using a Friction Stir
Weld method for near net-shape manufacture
and three-dimensional material processing
show promise, but much work will be
required to develop and perfect the
technique.
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).
Conclusion:
FINALLY, FSW IS AN ENVIRONMENTAL
FRIENDLY MANUFACTURING PROCESS
BEING USED AND PRESENTLY
UNDERGOING FURTHER RESEARCH
FOR BETTER UTILIZATION.
THANK YOU
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