2. Introduction
Welding using friction as the major resource
No filler material involved
Welds created by,
a) Frictional heating
b) Mechanical deformation
4. Friction Welding
Heat from mechanical energy conversion
Linear friction welding
Rotary friction welding
5. Friction Stir Welding
Shoulder which creates friction
heat
and welding pressure
Probe which Stir the material
Sufficient downward force to maintain
pressure and to create friction heat
Rotating probe
provides friction
heat and pressure
which joins the
material
Sufficient
downward force
to maintain
pressure and to
create friction
heat
6. 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)
13. Some of the FSW Machines
ESAB SuperStir TM machine FW28 ESAB Machine
14. 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
15. Comparison with other joining processes
FSW vs Fusion Welding FSW vsRivetting
» 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 Count
» Reduced Production
Time
» Reduced Defect Rates
» Increase in Load
Carrying Capability»
Improved Fracture
Performance
» Eliminates Consumables
» Less Operator
Dependent
16. 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)
17. 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