1
16 April 2015
FRICTION STIR WELDING/
PROCESSING
-the technology & future potential
By
M. Puviyarasan Research Scholar
Department of Mechanical Engineering
College of Engineering Guindy campus
Anna University, Chennai -25
1. Joining Processes – Intro.
2. Importance of FSW : A Case study
3. Friction Stir Welding – Intro.
4. What happens inside?
5. The Process
6. Pros and Cons
7. Why it is better?
8. Related Processes
9. Real time applications
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg..
3
Sl. No. CONTENTS Assembly vs Joining
Almost all products are assemblies of a
large number of components.
Some of the components or subassemblies
can move with respect to each other -
kinematic joint.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 4
The term assembly usually refers to
mechanical methods of fastening
parts together.
Some of these methods allow for
easy disassembly, while others do
not.
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Assembly vs Joining
Many components are physically fixed
together, with no relative motion
possible - Rigid joint (Structure).
Joining is generally used for welding,
brazing, soldering, and adhesive
bonding, which form a permanent joint
between the parts—a joint that cannot
easily be separated.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 5
Section of Tsing Ma Bridge being lifted, before joining
To restrict some degrees of freedom of motion for components (i.e.
to make mechanisms).
A complex shaped component may be impossible/expensive to
manufacture, but it may be possible/cheaper to make it in several
parts and then join them.
Some products are better made as assemblies, since they can be
disassembled for maintenance.
Transporting a disassembled
product is sometimes
easier/feasible compared to
transporting the entire product.
Why do we need Welding (joining)?
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 6
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 7
History of Welding
The earliest examples come from the Bronze and Iron
Ages in Europe and the Middle East.
Welding was used in the construction of the Iron pillar of Delhi,
erected in Delhi, India about 310 AD and weighing 5.4 metric tons.
1885 - Welding with carbon electrode.
1886 - Resistance butt welding.
1902 - oxy – acetylene welding (due to Production of cheap oxygen )
1907 - Coated electrodes were developed.
1930 - Release of stud welding, became popular in shipbuilding and
construction.
1930 - Submerged arc welding ;continues to be popular today.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 8
3
History of Welding cont.
1941- Gas tungsten arc welding, was finally perfected.
1950 - Shielded metal arc welding was developed.
1957 - flux-cored arc welding process ; Plasma Arc Welding.
1958 - Electron beam welding.
1960 - laser beam welding, high-speed, automated welding.
1967 - Magnetic pulse welding .
1991 - Friction stir welding (FSW) was invented by Wayne Thomas
at The Welding Institute (TWI, UK) and found high-quality
applications all over the world.
2000 – Friction Stir Processing (FSP) and related processes
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 9 16 April 2015
M. Puviyarasan, Research Scholar/Associate Professor, Mech. Engg.. Slide 10
Friction stir welding requires no blow torches
and no solder.
It literally "stirs" materials together at a
molecular level using friction.
Learn why this matters in OUR life!!
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 11
Importance of FSW
A Case study
Columbia Launch: 16 January 2003
Space Transportation System (STS) - 107
16 April 2015 M. Puviyarasan, Research Scholar/Associate Professor, Mech. Engg.. 12
Columbia Disaster February 1, 2003,
Columbia
disintegrated over Texas and Louisiana
as it reentered Earth's atmosphere
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Importance of FSW : A Case study cont. The tragedy of space shuttle Columbia happened on February 1,
2003 as it was reentering earth’s atmosphere.
The shuttle fell into pieces without any notice.
Subsequently, it was realized that the cause of failure was the loss of
a piece of foam insulation on an external tank at the time of
launching.
On reentering the atmosphere of earth at a speed of the 23 Mach,
wings of the shuttle experience temperature of 2800°F.
Investigation team of NASA smelt aluminum on thermal tiles plus the internal
edges of the left wing of the spacecraft, supporting the idea that the Columbia’s
destruction was because of hot gases that pierced through the damaged part of
the wing.
An unfortunate engineering disaster of modern times! 16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 13
Importance of FSW : A Case study cont. The failure of the crew module resulted from the thermal degradation
of structural properties, which resulted in a rapid catastrophic
sequential structural breakdown rather than an instantaneous
"explosive" failure.
After the loss of space shuttle Columbia in February 2003, NASA
redesigned and improved many components of the structures of the
external tanks and the application processes of the all important foam,
also known as the Thermal Protection System or TPS.
Major improvements have been made to the tank’s forward bipod
fitting area, the liquid hydrogen tank Ice Frost Ramps, the intertank
flange area, and the liquid oxygen feedline brackets and bellows.
The tank’s protuberance air load ramps — known as PAL ramps —
were also removed.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 14
Importance of FSW : A Case study cont. In 1993, NASA challenged Lockheed Martin Laboratories in Baltimore,
Md., to develop a high-strength, low-density, lighter-weight
replacement for aluminum alloy Al 2219–used on the original Space
Shuttle External Tank.
The External Tank Project Managers chose to use the Friction Stir
Welding process on its Super Light Weight Tank, which is made from
Al-Li 2195.
The Friction Stir Welding process produces a joint stronger than the
fusion arc welded joint, obtained in the earlier Light Weight Tank
program.
The increase in joint strength combined with the reduction in process
variability provides for an increased safety margin and high degree of
reliability for the External Tank.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 15
Importance of FSW : A Case study cont. The newest tanks, including ET-134, have been welded using a
new welding technology called Friction Stir Welding, a
technique better than conventional fusion welding.
Friction stir welding is different in that the materials are not melted.
Weld joints are more efficient, yielding 80 percent of the base
strength.
Fusion welding averages 40 to 50 percent of the base material’s
strength.
ET-134 is the first external tank to have most of its liquid hydrogen
tank welding performed by friction stir welding.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 16
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16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 17
Series of images showing
various stages of the process
to assemble an external tank.
ET-134 is the first external tank
to have most of its liquid
hydrogen tank welding
performed by friction stir
welding.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 18
The first space shuttle external tank to be partially built using the friction stir welding technique.
Several graphic images show the internal and external views of the Liquid Oxygen Tank, Intertank, Liquid Hydrogen Tank and
a completed external tank with thermal protection system.
Image credit: NASA/MSFC
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg..
Slide 19
Its journey from NASA’s Michoud Assembly Facility in New Orleans to the Kennedy Space Center, Florida, was loaded onto a barge to begin its six-day, 900-
mile journey to the Kennedy Center.
Friction Stir Welding – Intro.
FSW was invented at “The Welding
Institute “(TWI) of the United Kingdom in
1991.
It’s a Solid-state joining technique and
was initially applied to aluminum
alloys.
The basic concept of FSW is
remarkably simple.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 20
A nonconsumable rotating tool with a specially
designed pin and shoulder is inserted into the
abutting edges of sheets or plates to be joined
and subsequently traversed along the joint line.
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Friction Stir Welding – Intro.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 21
Two discrete metal workpieces butted together, along with
the tool (probe).
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 22
Fri
ctio
n S
tir
Wel
din
g P
roce
ss f
low
ch
art
Friction Stir Welding – The Process
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 23
Here, the advancing side is on the right, where the tool rotation
direction is the same as the tool travel direction (opposite the
direction of metal flow), Friction stir welding (FSW) is a relatively
new solid-state joining process.
Shoulder
Pin / Probe
Friction Stir Welding – The Process
The tool serves three
primary functions.
1. Heating of the workpiece
2. Movement of material to
produce the joint, and
3. Containment of the hot metal
beneath the tool shoulder.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 24
•Heating is created within the workpiece both by friction between the rotating tool pin and
shoulder and by severe plastic deformation of the workpiece.
•The localized heating softens material around the pin and, combined with the tool rotation and
translation, leads to movement of material from the front to the back of the pin, thus filling the
hole in the tool wake as the tool moves forward.
•The tool shoulder restricts metal flow to a level equivalent to the shoulder position, that is,
approximately to the initial workpiece top surface.
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Friction Stir Welding – The Process
As a result of the tool action, when performed properly, a solid-state
joint is produced, that is, no melting.
Because of various geometrical features on the tool, material
movement around the pin can be complex, with gradients in strain,
temperature, and strain rate.
In spite of the local microstructural in-homogeneity, one of the
significant benefits of this solid-state welding technique is the fully
recrystallized, equiaxed, fine grain microstructure created in the
nugget by the intense plastic deformation.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 25
FSW: Process Parameters
Tool rotational speed
Welding speed (Traverse feed)
Axial force
Shoulder diameter
Pin diameter and profile
Tilt angle
Work piece material
Shoulder and pin material
All these variables may affect the characteristics of the weld joint
significantly.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 26
FSW: Process Parameters Cont.
Tool rotational speed is the rotation speed of friction stir
welding tool and can be directly related to the frictional
heat generation.
The term welding speed is preferred to transverse speed,
which is the rate of travel of tool along the joint line.
Tool rotational speed and welding speed decide whether
enough heat input is being supplied to weld so as to
favourably affect the weld characteristics.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 27
FSW: Process Parameters Cont.
Tool Tilt Angle
Forces are important
parameters parts of
friction stir welding
technology.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 28
The force applied parallel to the axis of rotation of the
tool (Z-direction) is the downward force or Axial force.
Insufficient and excessive downward force produce
defects in the weld.
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FSW: Process Parameters Cont.
The defect free weld is decided by the use of proper tool
design.
Tool consists of three parts, these are shoulder, pin and shank.
Pin having small diameter and plunged into the work piece materials
completely.
The pin is responsible for proper stirring of the material and
transportation of plasticized material from the leading edge of the tool
to trailing edge of the tool.
Shoulder is part of the tool which produces most of heat due to its
rubbing with work piece surface.
Shoulder generates the frictional heat and also prevents the escape of
the plasticized material from the upper surface of the work piece.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 29
The different micro structural zones existing after FSW
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 30
The different micro structural zones existing after FSW Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 31
• Unaffected material or parent metal:
This is material remote from the weld that has not been deformed and that, although it may
have experienced a thermal cycle from the weld, is not affected by the heat in terms of
microstructure or mechanical properties.
• Heat-affected zone:
In this region, which lies closer to the weld-center, the material has experienced a thermal cycle
that has modified the microstructure and/or the mechanical properties. However, there is
no plastic deformation occurring in this area.
• Thermomechanically affected zone (TMAZ):
In this region, the FSW tool has plastically deformed the material, and the heat from the
process will also have exerted some influence on the material. There is generally a distinct
boundary between the recrystallized zone (weld nugget) and the deformed zones of the TMAZ.
• Weld nugget:
The fully recrystallized area, sometimes called the stir zone, refers to the zone previously
occupied by the tool pin. The term stir zone is commonly used in friction stir processing, where
large volumes of material are processed.
The different micro structural zones existing after FSW Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 32
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What happens inside?
The FSW process consist of three phases:
The plunge phase: where the weld is initiated;
The main phase: where the weld is made; and
The termination phase: where the welding tool is
withdrawn from the workpiece.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 33
What happens inside?
The plunge phase consists of inserting the rotating welding
tool into the joint, at a specific rate.
Frictional heating and pressure, at the end of the pin, induce
work-piece material to displace, forming a ring of expelled,
plastically deformed material around the pin as the pin enters
the work-pieces.
As the tool is plunged into the joint, heat is generated into
the surrounding material.
Once the welding tool is plunged into the work-piece, it
rotates at several hundred rpm and heat is generated between
welding tool and work-piece to reach a higher temperature.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 34
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 35
THE MACHINE
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg..
Slide 36
The world’s largest friction stir welding machine, designed to manufacture core stages for NASA’s heavy-lift SLS.
At 170 ft. tall, the friction stir welder that will assemble SLS core stages
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16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg..
Slide 37
Custom-built machines for welding long extrusions
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg..
Slide 38
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg..
Slide 39
Articulated and Parallel-Kinematic arm robot
16 April 2015 M. Puviyarasan, Research Scholar/Associate Professor, Mech. Engg..
Slide 40
An indigenously
developed servo
controlled
friction stir
welding/processing
machine
@
Anna University,
Chennai - 25
Funding Agency: DST/SERB, Govt. of India.
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What happens inside
Material flow:
The material flow during FSW is complicated and the understanding
of deformation process is limited.
Many factors would influence the material flow during FSW.
These factors include tool geometry (pin and shoulder design,
relative dimensions of pin and shoulder), welding parameters (tool
rotation rate and direction, i.e., clockwise or counter clockwise,
traverse speed, plunge depth, spindle angle), material types,
workpiece temperature, etc.
It is very likely that the material flow within the nugget during FSW
consists of several independent deformation processes.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 41
What happens inside
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 42
Metallurgical processing zones developed during friction stir welding
What happens inside
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 43
Metal flow patterns
What happens inside
Heat flow:
FSW results in intense plastic deformation around rotating tool and
friction between tool and workpieces.
Both these factors contribute to the temperature increase within
and around the stirred zone.
Since the temperature distribution within and around the stirred
zone directly influences the microstructure of the welds, such as
grain size, grain boundary character, coarsening and dissolution of
precipitates, and resultant mechanical properties of the welds, it is
important to obtain information about temperature distribution
during FSW.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 44
12
What happens inside
However, temperature measurements within the stirred
zone are very difficult due to the intense plastic
deformation produced by the rotation and translation of
tool.
The maximum temperatures within the stirred zone during
FSW have been either estimated from the microstructure of
the weld or recorded by embedding thermocouple in the
regions adjacent to the rotating pin.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 45
Welding tools for FSW
Welding tool geometry development led to sound
welds.
Advancement in Tools led to: Higher weld production
speeds, higher workpiece thickness, improved joint
property.
Has enabled welding of high melting point materials,
such as titanium, steel, and copper
New welding tool features have been developed with,
for the goal of reducing process forces, increasing the
robustness of the process, or simplifying welding
control. 16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 46
Welding tools for FSW Cont.
Different features are used by different practitioners
of FSW, depending on the materials being welded
and the process performance goals required.
FSW practitioners needing to weld at higher travel
speeds or with deeper weld penetration may adopt
variations to the original tool design.
Tool steel materials are generally acceptable for the
FSW of aluminium alloys.
Even for welding aluminium alloys there is no
accepted standard tool material.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 47
Welding tools used for FSW Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 48
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Welding tools used for FSW Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 49
Bobbin Tool
Advantages
Environmental benefits:
No harmful emissions are created during welding, thereby
making the process environmentally friendly.
No shielding gas required.
No/Minimum surface cleaning required.
Eliminate grinding wastes.
Eliminate solvents required for degreasing.
Consumable materials saving, such wire or any other gases.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 50
Advantages Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 51
Metallurgical benefits:
Solid phase process.
Low distortion of workpiece.
Good dimensional stability and repeatability.
No loss of alloying elements.
Excellent metallurgical properties in the joint area.
Fine microstructure.
Absence of cracking.
Replace multiple parts joined by fasteners.
Advantages Cont.
Energy benefits:
Improved materials use (e.g., joining different thickness)
allows reduction in weight.
Only 2.5% of the energy needed for a laser weld.
Decreased fuel consumption in light weight aircraft,
automotive and ship applications.
It’s a “green” technology due to its energy efficiency,
environmental friendliness, and versatility.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 52
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Limitations
Exit hole left when tool is withdrawn.
Large down forces required with heavy-duty clamping
necessary to hold the plates together.
Less flexible than manual and arc processes (difficulties with
thickness variations and non-linear welds).
Often slower traverse rate than some fusion welding
techniques, although this may be offset if fewer welding
passes are required. (up to 750mm/min for welding 5mm
thick 6000 series aluminum alloy on commercially available
machines).
Backing bar is sometimes required.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 53
Limitations
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 54
Underwater FSW
Many researchers have conducted underwater FSW, during
which the whole work piece was immersed in the water
environment.
The results indicated that the tensile strength of the
underwater joint was higher than that of the normal joint,
confirming the feasibility of underwater FSW to improve the
joint properties.
Underwater FSW creates a milder and lower thermal cycle
than traditional FSW which is helpful to reserve the excellent
performance of base metal furthest.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 55
Underwater FSW Cont.
Water environment
has reduced the
residual stress of the
joint obviously and
even reserved
compression stress
in the weld.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 56
The mechanical and microstructural properties
are higher than that of the normal FSW joint.
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FRICTION-STIR PROCESSING
FRICTION STIR PROCESSING (FSP) is an adaptation of friction
stir welding.
The unique features of friction stir welding can be used to develop new
processes based on the concept of friction stirring:
Low amount of heat generated
Extensive plastic flow of material
Very fine grain size in the stirred region
Healing of flaws and casting porosity
Random misorientation of grain boundaries in the stirred region
Mechanical mixing of the surface and subsurface layers
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 57
FRICTION-STIR PROCESSING
FSP can be used as a generic process to modify the
microstructure and change the composition, at selective
locations.
At this time, FSP is the only solid state processing
technique that has these unique capabilities.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 58
16 April 2015 59
FSP
Rotating Tool Pin is plunged into workpiece
Tool traverses on the plate until a fully recrystallized
fine grain microstructure is obtained
Shoulder touches the surface
FRICTION-STIR PROCESSING Cont.
MICROSTRUCTURAL MODIFICATION
During FSP, the rotating pin with a threaded design produces
an intense breaking and mixing effect in the processed zone,
thereby creating a fine, uniform, and densified structure.
Therefore, FSP can be developed as a generic tool for
modifying the microstructure of heterogeneous metallic
materials such as cast alloys, metal matrix composites, and
nanophase aluminum alloys prepared through the PM
technique.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 60
16
FRICTION-STIR PROCESSING Cont.
MICROSTRUCTURAL MODIFICATION
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 61
Optical micrographs showing morphology and distribution
of Si particles in A356 samples:
(a) as-cast and (b) FSP at 900 rpm
16 April 2015 62
Composite Fabrication using FSP
Fabricating composites through FSP results in:
Good Interface bonding between particles and
reinforcements.
Reduces Hydrogen porosity, common in composites
fabricated through stir casting.
Reduced distortion and defects in materials.
FRICTION STIR PROCESSING though developed as a
grain refinement technique, can be applied
successfully in fabricating composites.
Composite Fabrication using FSP Contd.
SURFACE/BULK COMPOSITE
The use of the FSP technique results in the intense plastic
deformation and mixing of material in the processed zone;
incorporate the ceramic particles into the metallic
substrate plate, to form the surface/Bulk composites.
A groove can be cut on the plate, and the particles filled
into the groove.
With deeper grooves being cut, it is possible to fabricate
bulk composites via. FSP
The bulk composites fabricated via FSP showed enhanced
hardness and strengths.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 63
Composite Fabrication using FSP Contd.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 64
Optical micrograph showing surface composite layers
fabricated by FSP in (a) A356 and (b) 5083Al substrates
17
Composite Fabrication using FSP Contd.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 65
SEM micrographs showing the SiO2 particle dispersion in
the SiO2/AZ61 composite prepared by FSP
FRICTION-STIR PROCESSING
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 66
Applications
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 67
Engineers at NASA's Marshall Space Flight Center have
worked to perfect the FSW technique, which will be used
to help send astronauts to the moon
and further in space travel.
It might also make better products --
ships, cars, trains -- for use here on Earth.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 68
Aerospace industry include:
Wings, fuselages, empennages,
Cryogenic fuel tanks for space vehicles,
Aviation fuel tanks, external throw away tanks for
military aircraft,
Military and scientific rockets,
Repair of faulty MIG welds.
18
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 69
Four aluminum domes, each created using innovative friction stir welding processes, are seen in this overhead view of the
Marshall Space Flight Center.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 70
Achieved high-strength,
defect free, uniformly
bonded aluminum structures
- a vital requirement for
next-generation
launch vehicles and
hardware designed for
long-term space
travel.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 71
Successfully
manufactured tank
dome which ensures the
strength and reliability
of these novel tank
forming processes.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 72
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Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 73
NASA has invested in the Friction Stir Weld
Spun Form Dome Project since 2005
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 74
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 75
Shipbuilding and marine industries include:
Panels for decks, sides, bulkheads and floors,
Aluminum extrusions, hulls and superstructures,
Helicopter landing platforms,
Offshore accommodation, marine and transport
Structures, masts and booms,
e.g. for sailing boats, refrigeration plant.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 76
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Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 77
Land transportation includes:
Engine and chassis cradles, wheel rims, tailored
blanks, e.g. welding of different sheet thicknesses,.
Truck bodies, tail lifts for lorries, mobile cranes,
Armor plate vehicles, fuel tankers, caravans, buses
and airfield transportation vehicles.
Motorcycle and bicycle frames, articulated lifts and
personnel bridges, skips, repair of aluminum cars,
magnesium and magnesium/aluminum joints.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 78
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 79
The process is also used to fabricate suspension rods,
steering columns, gear box forks and drive shafts.
As well as engine valves, in which the ability to join
dissimilar materials means that the valve stem and head
can be made of materials suited to their different duty
cycles in service.
Wheel assemblies using two aluminum alloys have
been made in which the butt or lap welds can be
fabricated in wrought and/or cast materials
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 80
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Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 81
Construction industry includes:
Aluminum bridges, facade panels made from aluminum,
copper or titanium, window frames, aluminum pipelines,
aluminum reactors for power plants and the chemical
industry, heat exchangers and air conditioners and pipe
fabrication.
FSW has also been used to weld lightweight panels made of
plastic foam sandwiched between two sheets of aluminum,
for which any fusion welding technique would encounter
serious problems because of the much higher temperatures
involved.
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 82
Section of Tsing Ma Bridge being lifted, before joining
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 83
Construction industry includes:
Foamed aluminum
Applications under review include the bodies and floors of
coaches and buses, military bridge-laying vehicles (and
bridges/pontoons), and waste skips .
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 84
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Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 85
Other industry sectors includes:
Refrigeration panels
Cooking equipment
Gas tanks and gas cylinders
Furniture
Connecting aluminum or copper coils in rolling mills
Applications Cont.
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 86
Applications
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 87
Image Credits
16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 88
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16 April 2015 M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. Slide 89
Thank you
M. Puviyarasan,Research Scholar/Associate Professor, Mech. Engg.. 16 April 2015 Slide 90
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