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Friction stir-welding (2)

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This document provides an overview of friction stir welding (FSW), including its principles, setup, materials used, advantages, and applications. Some key points: - FSW was invented in 1991 as a solid state welding process that generates frictional heat between a rotating tool and materials to be joined, below their melting points. - It overcomes issues with conventional welding like distortion and defects, and enables welding of materials not possible with fusion welding. - The FSW setup involves a cylindrical, shouldered tool with a probe that is rotated and plunged into materials to be joined. This generates frictional heat to plasticize the materials without melting. - FSW produces high strength welds in a wide

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FRICTION STIR WELDING PRESENTEDBY SIVAPRASADSS 10418043 S7 ME PRSCET
CONTENTS • INTRODUCTION • PRINCIPLES OF FSW WELDING • FSW SET UP • MATERIALS USED • STRESS -STRAIN GRAPH • COMPARISONS • ADVANTAGES • DISADVANTAGES • APPLICATIONS • FUTURE DEVELOPMENTS • CONCLUSIONS • REFERENCES
INTRODUCTION • FSW was invented by Wayne Thomas at TWI(The Welding Institute) Ltd in 1991. • It overcomes many of the problems associated with conventional joining techniques. • FSW 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.
WELDING • Welding is a joining process. • Application of heat. • With / without application of pressure& electrode. • Making permanent joints.
CLASSIFICATION OF WELDING • Main two classifications are • Fusion welding  heated to molten state  no pressure required  eg:Gas welding, Arc welding • Plastic welding  heated to plastic state  pressure required  eg:friction welding,forge welding
WORKING PRINCIPLE OF FSW • FSW a cylindrical, shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two pieces butted together. • Frictional heat is generated between the wear resistant welding tool and the material of the work pieces.
WORKING PRINCIPLE OF FSW • The plasticized material is transferred the front edge of the tool to back edge of the tool probe and it’s forged by the intimate contact of the tool shoulder and pin profile. • This heat is without reaching the melting point and allows traversing of the tool along the weld line.
EXPERIMENTAL SETUP OF FSW
Welding Steel using FSW
IMPORTANT WELDING ZONES • Friction stir weld in its cross-section consists of three main zones: (a) Nugget, stirred zone, (b) thermo-mechanically affected zone (TMAZ) (c)heat affected zone (HAZ). • The three zones pose distinct mechanical properties and nugget and TMAZ being the weakest part of the joint.
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
Tools Parameters •H13 steel tools are used •Tool is strong, tough, hard wearing at welding temperatue •Have good oxidation resistance, thermal conductivity
Common Tools Fixed Pin ToolSelf Reacting Pin Tool Adjustable Pin Tool Retractable Pin Tool/Removable type
Some of the FSW Machines ESAB SuperStir TM machine FW28 ESAB Machine
STRESS VS STRAIN GRAPH
Comparison with other joining process FSW vs Fusion Welding » Good Mechanical Properties by weld at below MP of workpiece » Reduced Distortion » Reduced Defect Rate » Parent Metal Chemistry » Simplifies Dissimilar Alloy Welding » Eliminates Consumables » Reduces Health Hazard &no weld pool
Advantages  Good mechanical properties as in weld condition  Improved saftey due to absence of toxic fumes  No consumables  Easily automated on simple milling machines  Can operate on all positions (vertical,horizontal) etc  Low environment impact  High superior weld strength
Disadvantages  Work pieces must be rigidly clamped  Slower traverse rate than fusion welding
APPLICATIONS • AEROSPACE • SHIP BUILDING & OFFSHORE • AUTOMOTIVE • FABRICATIONS • RAILWAYS
Future Developments  Laser-assisted friction stir welding  Possible use of induction coil and other mechanism
Conclusion  FSW opening up new areas of welding daily  No distortion,spatter,fumes  Welding at below m.p of work piece  Good forging action by tool  Create high strength weld in hard materials  It is alternative to fusion welding
REFERENCES [1].M. Jeyaraman, R. Sivasubramanian, V .Balasubramanian “Optimizationof process parameters forfrictionstirweldingof cast aluminiumalloyA319 byTaguchimethod”. Journal of material processing technology 2 0 0 (2008)364–372 . [2].P. Hema, S.M. Gangadhar, K. Ravindranath, “Optimizationof Process Parameters for FrictionStirWeldingof AluminiumAlloy6061usingANOVA”. International Journal of Mechanical and Production Engineering,Vol.2, Issue 1 (2012) 36-42. [3] L.Dubourg, A.Merati, M.Jahazi, “Process optimizationandmechanicalproperties of frictionstirlapwelds of7075-T6stringerson2024-T3skin”. The Journal of Materials and design31 (2010) 3324–3330.
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Friction stir-welding (2)

  • 2. CONTENTS • INTRODUCTION • PRINCIPLES OF FSW WELDING • FSW SET UP • MATERIALS USED • STRESS -STRAIN GRAPH • COMPARISONS • ADVANTAGES • DISADVANTAGES • APPLICATIONS • FUTURE DEVELOPMENTS • CONCLUSIONS • REFERENCES
  • 3. INTRODUCTION • FSW was invented by Wayne Thomas at TWI(The Welding Institute) Ltd in 1991. • It overcomes many of the problems associated with conventional joining techniques. • FSW 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.
  • 4. WELDING • Welding is a joining process. • Application of heat. • With / without application of pressure& electrode. • Making permanent joints.
  • 5. CLASSIFICATION OF WELDING • Main two classifications are • Fusion welding  heated to molten state  no pressure required  eg:Gas welding, Arc welding • Plastic welding  heated to plastic state  pressure required  eg:friction welding,forge welding
  • 6. WORKING PRINCIPLE OF FSW • FSW a cylindrical, shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two pieces butted together. • Frictional heat is generated between the wear resistant welding tool and the material of the work pieces.
  • 7. WORKING PRINCIPLE OF FSW • The plasticized material is transferred the front edge of the tool to back edge of the tool probe and it’s forged by the intimate contact of the tool shoulder and pin profile. • This heat is without reaching the melting point and allows traversing of the tool along the weld line.
  • 10. IMPORTANT WELDING ZONES • Friction stir weld in its cross-section consists of three main zones: (a) Nugget, stirred zone, (b) thermo-mechanically affected zone (TMAZ) (c)heat affected zone (HAZ). • The three zones pose distinct mechanical properties and nugget and TMAZ being the weakest part of the joint.
  • 11. 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)
  • 12. Microstructure analysis Optical micrographs of regions (a), (b) and (c) of the stir nugget.
  • 13. Joint Geometries It can be used in all positions, •Horizontal •Vertical •Overhead •Orbital
  • 14. Material Suitability  Copper and its alloys  Lead  Titanium and its alloys  Magnesium alloys  Zinc  Plastics  Mild steel  Stainless steel  Nickel alloys
  • 15. Tools Parameters •H13 steel tools are used •Tool is strong, tough, hard wearing at welding temperatue •Have good oxidation resistance, thermal conductivity
  • 16. Common Tools Fixed Pin ToolSelf Reacting Pin Tool Adjustable Pin Tool Retractable Pin Tool/Removable type
  • 17. Some of the FSW Machines ESAB SuperStir TM machine FW28 ESAB Machine
  • 19. Comparison with other joining process FSW vs Fusion Welding » Good Mechanical Properties by weld at below MP of workpiece » Reduced Distortion » Reduced Defect Rate » Parent Metal Chemistry » Simplifies Dissimilar Alloy Welding » Eliminates Consumables » Reduces Health Hazard &no weld pool
  • 20. Advantages  Good mechanical properties as in weld condition  Improved saftey due to absence of toxic fumes  No consumables  Easily automated on simple milling machines  Can operate on all positions (vertical,horizontal) etc  Low environment impact  High superior weld strength
  • 21. Disadvantages  Work pieces must be rigidly clamped  Slower traverse rate than fusion welding
  • 22. APPLICATIONS • AEROSPACE • SHIP BUILDING & OFFSHORE • AUTOMOTIVE • FABRICATIONS • RAILWAYS
  • 23. Future Developments  Laser-assisted friction stir welding  Possible use of induction coil and other mechanism
  • 24. Conclusion  FSW opening up new areas of welding daily  No distortion,spatter,fumes  Welding at below m.p of work piece  Good forging action by tool  Create high strength weld in hard materials  It is alternative to fusion welding
  • 25. REFERENCES [1].M. Jeyaraman, R. Sivasubramanian, V .Balasubramanian “Optimizationof process parameters forfrictionstirweldingof cast aluminiumalloyA319 byTaguchimethod”. Journal of material processing technology 2 0 0 (2008)364–372 . [2].P. Hema, S.M. Gangadhar, K. Ravindranath, “Optimizationof Process Parameters for FrictionStirWeldingof AluminiumAlloy6061usingANOVA”. International Journal of Mechanical and Production Engineering,Vol.2, Issue 1 (2012) 36-42. [3] L.Dubourg, A.Merati, M.Jahazi, “Process optimizationandmechanicalproperties of frictionstirlapwelds of7075-T6stringerson2024-T3skin”. The Journal of Materials and design31 (2010) 3324–3330.