Community hub
Recent from talks
Knowledge base stats:
Talk channels stats:
Members stats:
Friction stir welding
Friction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. Heat is generated by friction between the rotating tool and the workpiece material, which leads to a softened region near the FSW tool. While the tool is traversed along the joint line, it mechanically intermixes the two pieces of metal, and forges the hot and softened metal by the mechanical pressure, which is applied by the tool, much like joining clay, or dough. It is primarily used on wrought or extruded aluminium and particularly for structures which need very high weld strength. FSW is capable of joining aluminium alloys, copper alloys, titanium alloys, mild steel, stainless steel and magnesium alloys. More recently, it was successfully used in welding of polymers. In addition, joining of dissimilar metals, such as aluminium to magnesium alloys, has been recently achieved by FSW. Application of FSW can be found in modern shipbuilding, trains, and aerospace applications.
The concept was patented in the Soviet Union by Yu. Klimenko in 1967, but it wasn't developed into a commercial technology at that time. It was experimentally proven and commercialized at The Welding Institute (TWI) in the UK in 1991. TWI held patents on the process, the first being the most descriptive.
Friction stir welding is performed with a rotating cylindrical tool which has a profiled pin (also known as a probe) having a diameter smaller than the diameter of its shoulder. During welding the tool is fed into a butt joint between two clamped workpieces, until the probe pierces into the workpiece and its shoulder touches the surface of the workpieces. The probe is slightly shorter than the weld depth required, with the tool shoulder riding atop the work surface. After a short dwell time, the tool is moved forward along the joint line at the pre-set welding speed.
Frictional heat is generated between the wear-resistant tool and the work pieces. This heat, along with that generated by the mechanical mixing process and the adiabatic heat within the material, cause the stirred materials to soften without melting. As the tool is moved forward, a special profile on the probe forces plasticised material from the leading face to the rear, where the high forces assist in a forged consolidation of the weld.
This process of the tool traversing along the weld line in a plasticised tubular shaft of metal results in severe solid-state deformation involving dynamic recrystallization of the base material.
The solid-state nature of the FSW process, combined with its unusual tool shape and asymmetric speed profile, results in a highly characteristic micro-structure. The micro-structure can be broken up into the following zones:
The solid-state nature of FSW leads to several advantages over fusion welding methods, as problems associated with cooling from the liquid phase are avoided. Issues such as porosity, solute redistribution, solidification cracking and liquation cracking do not arise during FSW. In general, FSW has been found to produce a low concentration of defects and is very tolerant to variations in parameters and materials.
Nevertheless, FSW is associated with a number of unique defects if it isn't done properly. Insufficient weld temperatures, due to low rotational speeds or high traverse speeds, for example, mean that the weld material is unable to accommodate the extensive deformation during welding. This may result in long, tunnel-like defects running along the weld, which may occur on the surface or subsurface. Low temperatures may also limit the forging action of the tool and so reduce the continuity of the bond between the material from each side of the weld. The light contact between the material has given rise to the name "kissing bond". This defect is particularly worrying, since it is very difficult to detect using nondestructive methods such as X-ray or ultrasonic testing. If the pin is not long enough or the tool rises out of the plate, then the interface at the bottom of the weld may not be disrupted and forged by the tool, resulting in a lack-of-penetration defect. This is essentially a notch in the material, which can be a potential source of fatigue cracks.
Hub AI
Friction stir welding AI simulator
(@Friction stir welding_simulator)
Friction stir welding
Friction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. Heat is generated by friction between the rotating tool and the workpiece material, which leads to a softened region near the FSW tool. While the tool is traversed along the joint line, it mechanically intermixes the two pieces of metal, and forges the hot and softened metal by the mechanical pressure, which is applied by the tool, much like joining clay, or dough. It is primarily used on wrought or extruded aluminium and particularly for structures which need very high weld strength. FSW is capable of joining aluminium alloys, copper alloys, titanium alloys, mild steel, stainless steel and magnesium alloys. More recently, it was successfully used in welding of polymers. In addition, joining of dissimilar metals, such as aluminium to magnesium alloys, has been recently achieved by FSW. Application of FSW can be found in modern shipbuilding, trains, and aerospace applications.
The concept was patented in the Soviet Union by Yu. Klimenko in 1967, but it wasn't developed into a commercial technology at that time. It was experimentally proven and commercialized at The Welding Institute (TWI) in the UK in 1991. TWI held patents on the process, the first being the most descriptive.
Friction stir welding is performed with a rotating cylindrical tool which has a profiled pin (also known as a probe) having a diameter smaller than the diameter of its shoulder. During welding the tool is fed into a butt joint between two clamped workpieces, until the probe pierces into the workpiece and its shoulder touches the surface of the workpieces. The probe is slightly shorter than the weld depth required, with the tool shoulder riding atop the work surface. After a short dwell time, the tool is moved forward along the joint line at the pre-set welding speed.
Frictional heat is generated between the wear-resistant tool and the work pieces. This heat, along with that generated by the mechanical mixing process and the adiabatic heat within the material, cause the stirred materials to soften without melting. As the tool is moved forward, a special profile on the probe forces plasticised material from the leading face to the rear, where the high forces assist in a forged consolidation of the weld.
This process of the tool traversing along the weld line in a plasticised tubular shaft of metal results in severe solid-state deformation involving dynamic recrystallization of the base material.
The solid-state nature of the FSW process, combined with its unusual tool shape and asymmetric speed profile, results in a highly characteristic micro-structure. The micro-structure can be broken up into the following zones:
The solid-state nature of FSW leads to several advantages over fusion welding methods, as problems associated with cooling from the liquid phase are avoided. Issues such as porosity, solute redistribution, solidification cracking and liquation cracking do not arise during FSW. In general, FSW has been found to produce a low concentration of defects and is very tolerant to variations in parameters and materials.
Nevertheless, FSW is associated with a number of unique defects if it isn't done properly. Insufficient weld temperatures, due to low rotational speeds or high traverse speeds, for example, mean that the weld material is unable to accommodate the extensive deformation during welding. This may result in long, tunnel-like defects running along the weld, which may occur on the surface or subsurface. Low temperatures may also limit the forging action of the tool and so reduce the continuity of the bond between the material from each side of the weld. The light contact between the material has given rise to the name "kissing bond". This defect is particularly worrying, since it is very difficult to detect using nondestructive methods such as X-ray or ultrasonic testing. If the pin is not long enough or the tool rises out of the plate, then the interface at the bottom of the weld may not be disrupted and forged by the tool, resulting in a lack-of-penetration defect. This is essentially a notch in the material, which can be a potential source of fatigue cracks.