Friction Stir Welding

MANUFACTURING TECHNOLOGY
FRICTION STIR WELDING
NAME-SHUBHAM MADHESIA
ROLL NO.-14135079
SUBMITTED ON-13/10/2015
DEPARTMENT-MECHANICAL ENGG.
WELDING-Welding is a process of joining similar metals by
application of heat with or without application of pressure or
addition of filler metal. It results in a continuity of homogeneous
materials of the composition and characteristics of two part which
are weld together.
FRICTION STIR WELDING-It is a solid state welding process in

which two parts are joined with the help of third tool which generate
friction between two parts causing softening of the parts due to heat
generated there. Now we stir the metal from edges of the both parts
and fill the gap between the two parts to join the both parts. This is
called friction stir welding. In this process, no fusion of metal take
place. So it is called a solid state welding process.
PROCEDURE-
 We fix our job in the welding machine.
 Now we give command to the machine according to our
required specification.
 Now we place the pin of diameter 4mm and length 6mm over
the part where we wants to weld.
 Now start the machine which rotate and feed rate is according
to the command.
 Pin apply pressure at that point and it forward which causes
heating there.
 By heating, that part became soft and pin now rotate at
inclination of 1o which stir the metal from the weld plate and fill
the gap to weld the both plate.
 Now we remove our job and do some cleaning action if
required.
fig. friction stir welding machine
ADVANTAGES OF FRICTION STIR WELDING-
 It is used for welding critical component like aluminium in
aerospace industry.
 This welding process is used to weld as thin as 1mm plate to as
thick as 30mm plate.
 During this process no spattering and fumes re produced.
 This welding process provides good finishing as compared to
other welding processes.
 The weld are produced with low heat input , so low distortion
and little micro-structural changes occur.
 The weld quality is high with less pores and uniform material
structure.
 So weld zone is strong as compared to fusion welding.
 It can operate in all positions.
 It is easily automated.
 No consumable required in this process.
fig. aluminium plate welded by friction stir welding
LIMITATION OF FRICTION STIR WELDING-

 At last when welding is finished there is always a impression
left of pin.
 It is less flexible i.e. we can't transport it to the welding place.
 It requires large down force and also large force to clamp the
both plate together.
 Slightly slower than other welding process.
APPLICATION-
This process is used in all critical components or sensitive parts like:-
1) Aerospace industry
2) Automobile industry
3) Ship building industry
4) Robotics
5) Railways
6) Computers
There are many more industry and fields where this welding process
is being used.
 Also this welding process is more safer than fusion welding

processes. Since it does not produce fumes and spattering.
 This process is also environment friendly.
WELDING PARAMETERS-
Transverse speed and tool rotation-Transverse speed means how
quickly tool transverse the interface, and tool rotation means how
fast it rotate. These two parameter are very important and it ensure
the good and efficient welding. For a successful welding it is required
that the metal which surrounds the tool is hot enough to produce
plastic deformation at lower down force acting on the tool. To
produce hot metal surrounding we have to increase the tool rotation
and decrease the transverse speed. If the material is too cold then
voids or other flaws may be present in the stir zone and in extreme
cases the tool may break.
Very large heat production also cause some problems i.e. it might
leads to change in microstructure of welded zone which become
weak.
fig. different parameters of friction stir welding

TOOL DESIGN- Tool design is also an important factor which
ensure quality weld and welding speed. Welding tool is sufficient
strong, tough and hard at welding temperature. Also it should be
oxidation resistant and have low thermal expansion to minimize heat
loss and thermal damage.
TOOL SPECIFICATION-Pin diameter used for welding is of 4mm.
Length of pin is 6mm.
fig. tools in friction stir welding machine
WELDING FORCES-There are many forces that act during

friction stir welding on the tool.
 A downward force act on pin which is required to maintain the
position of the tool at or below material surface.
 The traverse force acts parallel to the tool motion and is

positive in the traverse direction. This force arises as a result of
the resistance of the material to the motion of the tool.
 Torque is required to rotate the tool, the amount of which will
depend on the down force and friction coefficient (sliding
friction) or the flow strength of the material in the surrounding
region.
WELDING SPECIFICATION-
There are many tools are in friction stir welding machine. These are
pin, clamp(to hold the plate), shoulder(which hold the pin) etc.
SPECIFICATION-
Pin diameter-4mm
Pin length-6mm
fig. specification of friction stir welding
Shoulder diameter-20mm
Tilt angle-1o
Plate thickness-6mm
Spindle speed-1200rpm
Z axis load-600kg
Z axis displacement- -5.800

Z axis feed rate- 10mm/min
X axis feed rate- -100mm/min
RESULT-This welding process provides good surface finish and

uniform composition welded material due to less heating.

Friction Stir Welding

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MANUFACTURING TECHNOLOGY

FRICTION STIR WELDING

FRICTION STIR WELDING-It is a solid state welding process in

LIMITATION OF FRICTION STIR WELDING-

 Also this welding process is more safer than fusion welding

fig. different parameters of friction stir welding

TOOL SPECIFICATION-Pin diameter used for welding is of 4mm.

Length of pin is 6mm.

fig. tools in friction stir welding machine

WELDING FORCES-There are many forces that act during

 The traverse force acts parallel to the tool motion and is

fig. specification of friction stir welding

Z axis displacement- -5.800

X axis feed rate- -100mm/min

RESULT-This welding process provides good surface finish and

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