WELDING TECHNOLOGY

1. Friction Stir Welding (FSW)
GROUP-4
MADE BY :- MEET SHAH (156050319051)
JAINISH PATEL (156050319034)
KRUNAL CHAMPANERI (156050319004)
DEVARSH JOSHI (156050319015)
TAKSH PATEL (156050319041)
VEDANT PATEL (156050319042)
SUBJECT:- FABRICATION TECHNOLOGY

2. What is stir welding ?
•Stir welding is a solid state joining
process that uses a non consumable
toot to joint two facing work pieces
without melting the workpiece
material.

3. Introduction
• FSW was invented by Wayne Thomas in 1991.
• It is low energy input, capable of producing very
high strength welds in wide range of materials at
lower cost.
• FSW process takes place in the solid phase
below the melting point of the materials to be
joined.
• FSW welding belongs to plasticwelding
category. Due to,
• Heated to plasticstate
• Pressure required

4. Working principle
• Heat is generated by friction between rotating tool and the
workpiece material which leads to soften reign near the SFW
tool.

5. Process
• A cylindrical tool with a profiled threaded probe
is used
• The tool which rotated at constant speed andis
then placed between the workpiece materials.
• The metallic parts should be clamped properly
so the joint faces cannot be forced apart by the
process.

6. Tool parameters
• Tool :HSS (High SpeedSteel)
• Tool pin profile :Hexagonal
• Tool dimensions :
• Tool length = 80mm
• Tool diameter = 18mm
• Tool pin diameter = 6 mm
• Tool pin length = 5.8 mm
• Coating material :TiAlN (PVD – Physical Vapor Deposition )
• Coating thickness = 4mm
• Coating done in vaccum at low pressure in the temperature
range of 450-900c

7. Welding machine and tools

8. Comparison with other
welding
•Reduced distortion
•Reduced defectrate
•Simplifies dissimilar alloywelding
•Eliminate consumables
•Reduces health and hazard and no
weld pool

9. Advantages
• Good mechanical properties asin weld condition
• Improved safety due to absence of toxic fumes
• No consumables
• Easily automated on simple millingmachines
• Can operate on allpositons
• Low environment impact
• High superior weldstrength
• Generally good weldappearance

10. Disadvantages
• Exit hole left when tool is withdrawn.
• Large down forces required with heavy
duty clamping necessary to hold the plates
to weld.
• Slower traverse rate than fusion welding
• Less flexible than manual andarc
processes

11. Applications
• Shipbuilding and offshore :-hulls and
superstructure, helicopter landing platforms
• Aerospace :-wings ,fuselages ,empennages
• Automotive :-Aluminum engine cradlesand
suspension struts
• Railway rolling stock :-Railway tankersand
goods wagons
• Fabrications and robotics
• Personal computers :- components of computer

12. Conclusion
 Significance of FSW process
 Possible improvements
 Establishment in small scale industries

13. References
 Experimental study on the effect of welding speed and tool pin profiles
on AA6082-O aluminum friction stir welded butt joints, ‖ vol. 2, no. 5,
pp. 268–275, 2010. (Patil H. S)
 Effect of tool pin profile on mechanical properties of single and
double sided FSW AA19000 (Ram Niwas Bishnoi et.al.)
 Influence of Tool Design On the Mechanical Properties and
Microstructure in Friction Stir Welding of AA6351 Aluminium Alloy
(M. Karthikeyan., Dr.A.K.Shaik Dawood)
 Effect of tool pin profile on aluminum alloy using FSW for
optimum results by finding optimum parameters (V. Patel
Chandresh)
 Friction stir joining of aluminium alloys. Bulletin, November/December
1995, (Dawes C J, Thomas W M)

14. THANK YOU