FRICTION STIR WELDING

Introduction
Welding using friction as the
major resource
No filler material involved
Welds created by,
a) Frictional heating
b) Mechanical deformation

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

Sufficient downward force to maintain
pressure and to create friction heat

Shoulder which creates friction

heat
and welding pressure
Probe which Stir the material

Rotating
probe
provides
friction heat
and pressure
which joins
the material
Sufficient
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

Adjustable Pin Tool

Fixed Pin Tool

Retractable Pin Tool

Some of the FSW Machines

ESAB SuperStir TM
machine FW28

ESAB Machine

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

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

Reduced Part
FSW
Count
vsRivetting
Reduced
Production Time
Reduced Defect
Rates
Increase in Load
Carrying
Capability
Improved Fracture
Performance
Eliminates
Consumables
Less Operator
Dependent

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)

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

THANK
YOU