Advances in Friction Stir Welding and Future Directions

“ Prediction is very difficult – especially if it is about the future.” – Niels Bohr

Friction Stir Welding of Advanced Materials: Challenges D0000710 S. A David and Zhili Feng Materials Joining Group Metals and Ceramics Division Oak Ridge, TN 9th Materials Day in Graz In Honor of Professor H. Cerjak November 19, 2004 Graz, Austria

Significant advances have been made in the last two decades related to welding processes ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Growth of welding processes after the invention of electric arc ,[object Object],Friction Stir S.A. David and T. DebRoy, Science, v257 pp497-502, 1992

Friction stir welding process ,[object Object]

Friction stir welding and processing is a rapidly evolving technology ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Oak Ridge National Laboratory’s FSW/P machine is an enabler for concerted R&D ,[object Object],[object Object]

FSW R&D at ORNL ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Recent tool material development at ORNL shows tremendous potential ,[object Object],[object Object],[object Object],ORNL W-based alloy ORNL Ir-based alloy Tool pin holder

Steels and Ti alloys have been friction stir welded successfully using ORNL tool materials Ti-6-4, t=¼” SS304, t=¼”

Extensive thermomechanical processing can influence the phase stability of microstructures of FSW ,[object Object],[object Object],Ferrite content: 1.57% Base Metal Ferrite Stir Zone Ferrite content: 3.37% Sigma phase Ferrite

Friction stir welding is ideally suited for welding Al 2124- SiC composite ,[object Object],[object Object],FSW Laser

Friction stir welding for piping systems is being developed ,[object Object],[object Object]

Integrating FSW with other processes (hybrid) can improve process efficiency and tool life ,[object Object],4kW CW Nd:YAG laser with fiber optic delivery

Friction Stir Spot Welding (FSSW) can be a more efficient alternate process to electric resistance spot welding ,[object Object],[object Object],[object Object],[object Object],[object Object]

Mazda RX-8 Rear Door (Aluminum Panel) is Made by FSSW ,[object Object],(Courtesy of Ford)

Friction stir spot weld of Al 6111 Front side Back side

Changing from RSW to friction stir spot welding system has significant advantages water air Robot Cables Welding Gun Robot Controller Welding cable Welding trans. Electrode dresser junction box Welding controller Welding Power supply ,[object Object]

Friction stir spot welding system ,[object Object],[object Object],[object Object],(Courtesy of Ford) Robot Cables Welding Gun Robot controller

Friction Stir Processing: FSP can modify surface microstructure and improve properties ,[object Object],[object Object],[object Object],[object Object]

FSP produced very uniform distributions of fine particles in stir zones ,[object Object],[object Object],Shrinkage porosity was closed in stir zone

Typical tensile test results for A319 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

FSP increased the fatigue life of A356 ,[object Object],[object Object],93,848 43.9 19.4 0.002 FSP 7,700 39.0 15.5 0.002 As-cast Life, # of reversals Neuber stress range, ksi @ ½ life Stress amplitude, ksi @ ½ life Applied strain Condition

FSW has great potential for repair welding of irradiated materials ,[object Object],Asano et al. J. Nucl. Mat. 264 (1999)1-9 SS304L

Modeling effort at ORNL has shown that FSW drastically reduces the helium bubble growth, and could be developed as a viable repair technology for aging irradiated nuclear components FSW: max He bubble = 69 nm GTAW: max He bubble = 254 nm

Friction Stir Welding Modeling – from Process to Performance ,[object Object],[object Object],Hardness Velocity field around tool pin Trace Marker Predicted void location Void in actual weld Temperature Residual Stress Failure line in HAZ 55° Failure Prediction Under Loading Weld Centerline 55° Actual weld

Simulation captures the weakest link in an aluminum friction stir weld

Neutron scattering facility at ORNL has been used to investigate residual stress distribution in FSW

Summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

“ Before I came here I was confused about this subject. Having listened to your lecture I am still confused, but on a higher level.” – Enrico Fermi

Advances in Friction Stir Welding and Future Directions

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Advances in Friction Stir Welding and Future Directions