Design of friction welding

Probe and Analysis

GUIDE:- D.SHIVA KUMAR SIR.

BY,
Y.R.Sai Kiran (2451-10-736-118)
P.Varun (2451-10-736-108)
D.Srimanth(2451-10-736-086)
M.Sai Prasad(2451-10-736-076)
1

PROJECT REPORT
ON

FABRICATION OF WORKING MODEL OF FRICTION STIR

WELDING AND DESIGN OF PROBE AND ANALYSIS
Submitted in partial fulfillment of the requirement
For the award of the degree of
Bachelor of Engineering
In
Mechanical Engineering
By
Y.R.Sai Kiran Kumar Reddy
P. Varun
D.Srimanth
M.Sai Prasad

(2451-10-736-118)
(2451-10-736-108)
(2451-10-736-086)
(2451-10-736-076)

Under the esteemed guidance of

Mr.D.Shiva Kumar
Associate Professor
Mechanical Department

Dr.M.Madhavi
Head of Department
Mechanical Department

Department of Mechanical Engineering

MVSR Engineering College
Afflicted to Osmania University
Nadergul, Hyderabad
2010-2014
2

Maturi Venkata Subba Rao Engineering College

(Sponsored by Matrusri Education Society) Estd. 1981
Affiliated to Osmania University & Recognised by AICTE
Nadergul(P.O.), Hyderabad 501 510. Saroornagar Mandal. R.R.Dt. A.P.
Tel: +91-8415-244867, 244869 Telefax: +

MECHANICAL DEPARTMENT
CERTIFICATE
This is to certify that the project report entitled FABRICATION OF WORKING
MODEL OF FRICTION STIR WELDING AND DESIGN OF PROBE AND
ANALYSIS is a bonafide record of the work done by final year B.E Mechanical
Engineering students during the academic year 2010-2014 in partial fulfillments for
the award of the degree of Bachelor of Engineering.
NAME OF THE STUDENT

ROLL NO

Y.R.Sai Kiran Kumar Reddy

P.Varun
D.Srimanth
M.Sai Prasad

2451-10-736-118
2451-10-736-108
2451-10-736-086
2451-10-736-076

Internal Guide
Mr.D.Shiva Kumar
Associate Professor
Mechanical Department

Head of Department
Dr.M.Madhavi
Professor
Mechanical Department

ACKNOWLEDGEMENT

We take this opportunity to remember and acknowledge the cooperation, goodwill

and support both moral and technical extended by several individuals out of which
this project has evolved. We shall always cherish out associations with them.
We express our sincere gratitude to our guide Mr.D.Shiva Kumar sir for his
constant encouragement and support extended to us, during the course of our project
work in the highly enterprising field of FABRICATION OF WORKING
MODEL OF FRICTION-STIR WELDING AND DESIGN OF PROBE AND
ANALYSIS
We owe sincere thanks to our head of department Dr.D.Madavi and principal
P.A.Sastry for wholehearted Cooperation and encouragement in carrying out this
project work.

ABSTRACT
In order to improve material flow behavior during friction stir welding and avoid root flaws of
weld, a tool with a half-screw pin and a tool with a tapered-flute pin are suggested in this we
found out the effect of flute geometry in tool pins on material flow velocity is investigated by the
software ANSYS FLUENT. Numerical simulation results show that high material flow velocity
appears near the rotational tool and material flow velocity rapidly decreases with the increase of
distance away from the axis of the tool. Maximum material flow velocity by the tool with the
tapered-flute pin appears at the beginning position of flute and the velocity decreases with the
increase of flow length in flute. From the view of increasing the flow velocity of material near the
bottom of the work piece or in the middle of work piece, the tool with the half-screw pin and the
tool with the tapered-flute pin are both better than the conventional tool. And also fabrication of
simple Friction-Stir welding machine model.

INDEX

CHAPTER 1: INTRODUCTION

1.1 Introduction of the project.. 8

1.2 Project overview... 10

CHAPTER 2: THEORY ON FSW AND PROBE

2.1 Introduction to Solid state welding 12

2.2 Friction Welding.. 12
2.3 Types of Friction Welding... 17
2.4 Rotary Friction Welding.. 18
2.4.1 Continuous Drive Friction Welding
2.4.2 Inertia Friction Welding
2.5 Linear Friction Welding

CHAPTER 3: FABRICATION OF FSW

3.1 Introduction
3.2 Different components
3.3 Assembly of FSW

CHAPTER 4: GEOMETRIC MODELLING AND ANALYSIS OF FSW PROBE

4.1 Introduction
4.2 Different Models of Probe
4.3 Geometrical modeling
4.4 Analysis on Material flow behavior of Probe
4.1.1 Mesh Generation
4.4.2 Material Parameters
4.4.3 Boundry Conditions

CHAPTER 5: RESULTS CONCLUSIONS AND FUTURE PROSPECTS

APPENDIX

CHAPTER 1

INTRODUCTION

1.1) INTRODUCTION:-

Over the years there has been many attempts to describe the phenomena of friction.
It has been a problem for mankind throughout the ages. As man became more inventive, surfaces
and materials were called upon to perform more complex tasks. As machines were required to
move faster and last longer, the intricate problem of friction became more involved. This was due
to animal fats, all types of greases from mammals to fish, and eventually mineral oils. Refined
forms of oils and greases have been the principle method of placing a boundary layer between
metals in order to increase life and reduce wear.
Science and technology could not have advanced to where it is today without
understanding the mechanism of friction and wear. Today we are encountering even newer
requirements for longer life and faster speeds both in the air and on the ground. This has brought
about a new generation of metals and materials that have increased wear life primarily through
the reduction of friction between mating components. Some have taken the form of harder metal
alloys and others are surface enhancements that perform better than oils or greases.
Magnaplate has been in the forefront of almost all these newer materials. These
materials are composites and or alloys that are diffused into or onto base metal substrates. In
some cases, new oxides or harder porous metals are developed electrochemically or by plasma
spraying or in some cases, multi layers of soft and hard metals are deposited and then diffused
both into and on top of the base metal.
The ever-growing pace of technological advancement remains a bulwark to the nations
economy, which relies on innovative processes that drive growth, particularly ones that are
applicable to a range of industries. One such innovative process that continues to make its mark
felt across a variety of sectors is friction welding. Friction welding is a proven and cost-effective
method of joining similar or highly dissimilar materials that has proven to be very popular in
9

Europe and Asia, but is largely unknown and vastly underutilized in the United States. This is the
case despite the fact that it is a preferred method in the aircraft and automotive industries, and
ironically, the first patent for this process was introduced in the United States.
Friction welding (FW) is a fairly recent technique that utilizes a non-consumable
welding tool to generate frictional heat and plastic deformation at the welding location, there by
affecting the formation of a joint while the material is in solid state. The principal advantage of
frictional welding, being a solid state process, low distortion, absence of melt-related defects and
high joint strength, even in those alloys that are that are considered non-weldable by conventional
welding techniques.
Furthermore, friction welded joints are characterized by the absence of filler-induced
problems or defects, since the technique requires no filler, and by the low hydrogen contents in
the joints, an important consideration in welding steel and other alloys susceptible to hydrogen
damage.
FW can be used to produce butt, corner, lap, T, spot, fillet and hem joints, as well as to
weld hollow objects, such as tanks and tubes or pipes, stock with different thickness, tapered
section and parts with 3-dimensional contours. The technique can produce joints utilizing
equipment based on traditional machine tool technologies, and it has been used to weld a variety
of similar and dissimilar alloys as well as for welding metal matrix composites and for repairing
the existing joints. Replacement of fastened joints with FW welded joints can lead to significant
weight and cost savings, attractive propositions for many industries.
This report reviews some of the FW work performed to date, presents a brief account of
mechanical testing of welded joints, tackles the issue of generating joint allowables, and offers
some remarks and observation.
FW is a leap forward in manufacturing technology, a leap that will benefit a wide range
of industries, including transportation industry in general and the airframe industry in particular.
This Report describes a comprehensive evaluation of the energy input during Friction Welding
of medium carbon steel with different process.
10

Fig : 1.1.1, Friction welding of Two rods

1.2) Project Overview:The Project Fabrication of working model of FSW and Design of Probe and
analysis which gives us an overview of working of Friction-stir welding machine and the
importance of Probe in FSW and various paramaters that effect the effective working of the
Friction-stir welding probe.
It also gives us information about Material flow properties analysis which is very
important in FSW operations.

11

CHAPTER 2

THEORY ON FSW AND PROBE

2.1) SOLID STATE WELDING:12

Solid-state welding refers to joining processes in which coalescence results

from application of pressure alone or a combination of heat and pressure. If heat is used, the
temperature in the process is below the melting point of the metals being welded.

Fig : 2.1.1, Solid-State Welding Classification

2.2) Types of Solid State Welding:The solid-state welding group includes the oldest joining process as well as some of
the most modern. There are six types of solid state welding
1) Forge Welding
2) Cold Roll Welding
3) Diffusion Welding
4) Explosion Welding
5) Ultrasonic Welding
6) Friction Welding

13

2.2.1) Forge Welding:Forge welding is a welding process in which the components to be joined are heated
to hot working temperatures and then forged together by hammer or other means. Considerable
skill was required by the craftsmen who practiced it to achieve a good weld. The process is of
historic significance in the development of manufacturing technology; however, it is of minor
commercial importance today.

Fig : 2.1.2, Forge Welding Process

14

2.2.2) Cold Roll Welding:Cold roll welding is a solid-state welding process accomplished by applying high
pressure by means of rolls between clean contacting surfaces at room temperature. Metals to be
welded must be very ductile and free of work hardening. Contact surfaces must be exceptionally
clean. Metals such as soft aluminum, copper, gold and silver can be readily cold-welded. For
small parts, the forces may be applied by simple handoperated tools. For heavier work, powered
presses are required to exert the necessary force. Applications of cold welding include cladding
stainless steel to mild steel for corrosion resistance, making bimetallic strips for measuring
temperature, and producing sandwich strips for coins.

Fig: 2.1.3, Cold Roll Welding Process

2.2.3) Diffusion Welding:15

Diffusion Welding is a solid-state welding process that results from the application
of heat and pressure, usually in a controlled atmosphere, with sufficient time allowed for solidstate diffusion and coalescence to occur. Temperatures are well below the melting points of the
metals, and plastic deformation at the surfaces is only minimal.
Applications of diffusion welding include the joining of high-strength and refractory
metals in the aerospace and nuclear industries. The process is used to join both similar and
dissimilar metals, and in the latter case a filler layer of a different metal is often sandwiched
between the two base metals to promote diffusion. A limitation of the process can be the time
required for diffusion to occur between the faying surfaces; this time can range from seconds to
hours.

16

Fig: 2.1.4, Diffusion Welding

2.2.4) Explosion Welding:Explosion Welding is a solid-state welding process in which rapid coalescence of
two metallic surfaces is caused by the energy of a detonated explosive. The process for welding
one metal plate on another can be described with reference to the figure:

Fig: 2.1.5, Explosion Welding

In this setup, the two plates are in a parallel configuration, separated by a certain
gap distance, with the explosive charge above the upper plate, called the flyer plate. A buffer
layer (for example, rubber or plastic) is often used between the explosive and the flyer plate to
protect its surface. The lower plate, called the backer metal, rests on an anvil for support. When
17

detonation is initiated, the explosive charge propagates from one end of the flyer plate to the
other. The resulting high-pressure zone propels the flyer plate to collide with the backer metal
progressively at high velocity, so it takes on an angular shape as the explosion advances, as
illustrated in the sketch.
Explosion welding is commonly used to bond two dissimilar metals, in particular to
clad one metal on top of a base metal over large areas. Applications include production of
corrosion-resistant sheet and plate stock for making processing equipment in the chemical and
petroleum industries. The term explosion cladding is used in this context. No filler metal is used
in explosion welding, and no external heat is applied.
2.2.5) Ultrasound Welding:Moderate pressure is applied between the two parts and an oscillating motion at
ultrasonic frequencies is used in a direction parallel to the contacting surfaces. The combination
of normal and vibratory forces results in shear stresses that remove surface films and achieve
atomic bonding of the surfaces.

Fig: 2.1.6, Ultra-Sound Welding

2.3) Friction Welding:18

Friction welding is a solid-state welding process in which coalescence is achieved

by frictional heat combined with pressure. The heat is generated by the friction between the two
components surfaces, usually by rotation of one part relative to the other. Then the parts are
driven toward each other with sufficient force to form a metallurgical bond.
The axial compression force upsets the parts, and the material displaced produces a flash.
The flash must be subsequently trimmed to provide a smooth surface in the weld region. No filler
metal, flux, or shielding gases are required.
Machines used for friction welding have the appearance of an engine lathe. They require
a powered spindle to turn one part at high speed and a means of applying an axial force between
the rotating part and the non-rotating part.
With its short cycle times, the process is suitable for mass production. It is applied in the
welding of various shafts and tubular parts of similar or dissimilar metals. One typical application
of friction welding is to coalesce medium-carbon steel shanks to carbide tips in producing twist
drills.

19

Fig: 2.3.1, Friction Welding Process

2.4) Classification of Friction Welding:Different Types of Friction Welding Machines which are in use are1) Rotary Friction Welding
2) Spin Friction Welding
3) Linear Friction welding
4) Friction surfacing
5) Linear reciprocating Friction welding
20

6) Orbital Friction welding

7) Angular reciprocating Friction welding.
8) Radial Friction welding
2.4.1) Rotary Friction Welding:-

Rotary friction welding was the first of the friction processes to be developed
and used commercially. There are two process variants: direct drive rotary friction welding and
stored energy friction welding. The first one is the most conventional technique and usually is
simply known as friction welding. It consists in two cylindrical bars held in axial alignment.
The moving bar is rotated by a motor which maintains an essentially constant rotational speed.
The two parts are brought in contact under a pre-selected axial force and for a specified period of
time. Rotation continues until achieving the temperature at which metal in the joint zone reaches
the plastic state. Then, the rotating bar is stopped while the pressure is either maintained or
increased to consolidate the joint. The other variant of rotary friction welding is the stored energy
process, more often called inertia welding. The rotating component is attached to a flywheel
which is accelerated by a motor until a preset rotation speed is reached. At this point, drive to the
flywheel is cut and the rotating flywheel, with stored energy, is forced against the stationary
component. The resultant braking action generates the required heat for welding. Sometimes
additional pressure is provided to complete the weld.

CLASSIFICATION:-

Rotating Friction welding can be classified into two categories:1) Continuous drive Friction welding
2) Inertia Friction welding

1) Continuous Drive Friction Welding:-

21

One of the work pieces is attached to a rotating motor drive, the other is
fixed in an axial motion system. One work piece is rotated at constant speed by the motor. An
axial or radial force is applied. The variables that depend on continuous drive friction welding
1) Rotational speed
2) Heating pressure
3) Forging pressure
4) Heating time
5) Braking time
6) Forging time

Fig:2.4.1, Continuous Drive Friction Welding Process

22

2) Inertia Friction Welding:Inertia Friction Welding is a variation of friction welding in which the energy
required to make the weld is supplied primarily by the stored rotational kinetic energy of the
welding machine.
In Inertia Welding, one of the work pieces is connected to a flywheel and the other is
restrained from rotating. The flywheel is accelerated to a predetermined rotational speed, storing
the required energy. The drive motor is disengaged and the work pieces are forced together by the
friction welding force. This causes the faying surfaces to rub together under pressure.

23

The kinetic energy stored in the rotating flywheel is dissipated as heat through friction
at the weld interface as the flywheel speed decreases. An increase in friction welding force (forge
force) may be applied before rotation stops. The forge force is maintained for a predetermined
time after rotation ceases.
One of the work pieces is connected to a flywheel; the other is clamped in a nonrotating axial drive The flywheel is accelerated to the welding angular velocity. The drive is
disengaged and the work pieces are brought together. Frictional heat is produced at the interface.
An axial force is applied to complete welding. The variables that depend on inertia friction
welding are
1) Moment of inertia of the flywheel.
2) Initial flywheel speed.
3) Axial pressure.
4) Forging pressure.

Fig: 2.3.2, Inertia Friction Welding Process

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2.4.2) Spin Friction Welding:Spin welding systems consist of two chucks for holding the materials to be welded, one
of which is fixed and the other rotating. Before welding one of the work pieces is attached to the
rotating chuck along with a flywheel of a given weight. The piece is then spun up to a high rate of
rotation to store the required energy in the flywheel. Once spinning at the proper speed, the motor
is removed and the pieces forced together under pressure. The force is kept on the pieces after the
spinning stops to allow the weld to "set". This technique is also known as inertia welding,
rotational welding or inertial friction welding.

Four different phases can be distinguished in the vibration welding process; the solid
friction phase, the transient phase, the steady-state phase and the cooling phase. In the solid
25

friction phase, heat is generated as a result of the friction between the two surfaces. This causes
the polymer material to heat up until the melting point is reached. The heat generated is
dependent on the applied tangential velocity and the pressure. In the second phase, a thin molten
polymer layer is formed which grows as a result of the on going heat generation. In this stage heat
is generated by viscous dissipation. At first only a thin molten layer exists and consequently the
shear rate and viscous heating contributions are large. As the thickness of the molten layer
increases the degree of viscous heating decreases.
Thereafter, the melting rate equals the outward flow rate (steady state). As soon as this
phase has been reached, the thickness of the molten layer is constant. The steady-state is
maintained until a certain "melt down depth" has been reached at which point the rotation is
stopped.
At this point the polymer melt cools and solidification starts, while film drainage still
occurs since the welding pressure remains. After all the material has solidified, drainage stops
and the joint is formed.

2.4.3) Linear friction welding:Linear Friction Welding (LFW) is seen a key technology for the aerospace
industry as it enables the joining of difficult to bond materials, can be used as a repair process,
and to build the complex structures required for today's gas turbines.
Essentially, it is a non-melting fusion process producing high integrity welds with
little prior surface preparation required. Linear friction welding (LFW) is similar to spin welding
except that the moving chuck oscillates laterally instead of spinning. The speeds are much lower
in general, which requires the pieces to be kept under pressure at all times. This also requires the
parts to have a high shear strength.

Linear friction welding requires more complex machinery than spin welding, but
has the advantage that parts of any shape can be joined, as opposed to parts with a circular
26

meeting point. Another advantage is that in most instances quality of joint is better than that
obtained using rotating technique.
Linear friction welding, (so named because the relative motion is linear across the
interface, rather than rotary), is already used to join blades onto discs in the aero engine industry.
Lower cost linear friction welding machines are now being developed for automotive
applications, such as the fabrication of brake discs, wheel rims and engine parts. As the parts to
be welded are forced into intimate contact, a fully reversed motion is imposed on part of the
system.
This generates frictional heat in the immediate region about the weld plane, thereby
softening a finite volume of material. As the weld proceeds, a portion of this visco-plastic layer is
extruded at the periphery of the weld interface, in rippled sheets of metal known as flash. This
should ensure that any interfacial contaminant is expelled. The combination of fast joining times
of the order of a few seconds, and the direct heat input at the weld interface, gives rise to
relatively small heat affected zones.
This, by judicious selection of components geometry, this also limits process induced
distortions. To this date, precious little research has been done in the area of LFW. It is generally
accepted that friction welding can be separated into (i) a dry friction stage, followed by (ii) an
increased asperity contact, and (iii) some sort of steady state once the relatively high weld
temperature has been acquired. It is not clear how the surface contaminants are removed especially from the mid-point of the weld. The challenge lies with the tribology of the problem,
heat generation, heat conduction, and more importantly, the representation of the visco-plastic
material flow during steady state LFW.

27

Fig: 2.4.1, Linear Friction Welding

2.4.4) Friction surfacing:Friction Surfacing is a process derived from friction welding whereby a
coating material, in rod form (termed the Mechtrode TM) is rotated under pressure, generating
a plasticised layer in the rod at the interface with the substrate. By moving a substrate across
the face of the rotating rod a plasticised layer between 0.2-2.5mm thick is deposited
(depending on mechtrode diameter and coating material).
The resulting composite material is created to provide the characteristics
demanded by any given application.During the coating process, the applied layer of metal
reaches a temperature near the melting point whilst simultaneously undergoing plastic
deformation. The coating is thus the product of a hot forging action, as opposed to the casting
mechanism inherent in welding and spraying processes.

28

This important difference means that many of the defects commonly

associated with these techniques are avoided. Friction surfacing is a process derived from
friction welding where a coating material is applied to a substrate. A rod composed of the
coating material (called a mechtrode) is rotated under pressure, generating a plasticised layer in
the rod at the interface with the substrate. By moving a substrate across the face of the rotating
rod a plasticised layer is deposited between 0.22.5 millimetres (0.00790.098 in) thick
depending on mechtrode diameter and coating material.

Fig: 2.4.2, Friction Surfacing Process

2.4.5) Linear reciprocating friction welding:-

In linear vibration welding the materials are placed in contact and put under
pressure. An external vibration force is then applied to slip the pieces relative to each other,
perpendicular to the pressure being applied. The parts are vibrated through a relatively small
displacement known as the amplitude, typically between 1.0 and 1.8 mm, for a frequency of
vibration of 200 Hz (high frequency), or 24 mm at 100 Hz (low frequency), in the plane of the
joint. This technique is widely used in the automotive industry, among others.

29

A minor modification is angular friction welding, which vibrates the materials by

torquing them through a small angle.

Fig: 2.4.3, Linear Reciprocating Friction Welding Process

2.4.6) Orbital friction welding:-

Orbital friction welding is similar to spin welding, but uses a more complex machine to
produce an orbital motion in which the moving part rotates in a small circle, much smaller than
the size of the joint as a whole.

30

Fig: 2.4.4, Orbital Friction Welding

2.5) Friction Stir Welding(FSW):-

Friction stir welding also produces a plasticised region of material, but in a

different manner. A non-consumable rotating tool is pushed into the materials to be welded and
then the central pin, or probe, followed by the shoulder, is brought into contact with the two parts
to be joined. The rotation of the tool heats up and plasticises the materials it is in contact with
and, as the tool moves along the joint line, material from the front of the tool is swept around this
plasticised annulus to the rear, so eliminating the interface Friction stir welding (FSW) is a novel
welding technique invented by The Welding Institute (TWI) in 1991.
FSW is actually a solid-state joining process that is a combination of extruding and
forging and is not a true welding process. Since the process occurs at a temperature below the
melting point of the work piece material, FSW has several advantages over fusion welding. Parts
to be joined are clamped firmly. A rotating hardened steel tool is driven into the joint and
traversed along the joint line between the parts. The rotating tool produces friction with the parts,
generating enough heat and deformation to weld the parts together.

31

Fig: 2.4.5, Friction-Stir Welding Process

Some of the process advantages are given in the following list:

1.FSW is energy efficient.
2.FSW requires minimal, if any, consumables.
3.FSW produces desirable microstructures in the weld and heat-affected zones
4.FSW is environmentally "friendly" (no fumes, noise, or sparks)
5.FSW can successfully join materials that are "unweldable" by fusion welding methods.
6.FSW produces less distortion than fusion welding techniques.

2.6) Advantages of friction welding:Friction welding is economical in that it permits joining together different materials,
one of which may be inexpensive and its quality control cost is minimal with a guarantee of high
quality welds. Moreover, the weld cycle is extremely short, so that productivity is very attractive.
Friction welding process is suitable for mass production. The friction welding process is suitable
32

for non-homogeneous joints involving materials having quite different chemical , mechanical and
thermal properties. The process is suitable for automation and adoptable for robot use. Other
advantage as follows:
-Weld heat affected zone (HAZ) has a fine grain hot-worked structure, not a cast structure found
with conventional welding
- Material and machining cost savings
-100% Bond of full cross section
- High production rates
-Automatic repeatability
-Stronger than parent material, with excellent fatigue resistance
-Similar and dissimilar material joined with no added fluxes or filler metals
-low distortion, even in long welds
-excellent mechanical properties as proven by fatigue, tensile, bend tests
-no fume is produced
-no porosity
-no spatter
- no filler wire is required for welding
-no welder certification is required
-can operate in all positions
-more energy efficient than other welding technologies
-environmentally friendly process minimizes energy consumption and generate no smoke, gasses
or waste stream
-joint strength equal or greater than that of parent material
-join highly dissimilar metal combination to optimize your products quality and properties
-save labor, material and operations through near net size design
-join less costly, lighter or tubular material to expensive material.

33

2.7) Disadvantages of friction welding:The disadvantage of friction welding are that not every configuration is feasible, that a
machine of sufficient power is needed and that for short runs the process may not be economical.
Apart from the cost of equipment, which must be suitable for the intended joints, the friction
welding process has some costs in tooling and set up that must be taken into account when
calculating the costs per weld. Tight concentricity requirements ,when needed may be difficult to
meet. Also finishing operations may be requested which sum up to the total cost.

1.

Simplicity of operation and simple equipment.

2.

Less time requirement.

3.

Low Surface impurities and oxide films.

4.

Compare to resistance butt welding produces improved welds at higher speed and lower

cost, less electric current is required.

5.

Heat affected zone is small as compare to conventional flash welding.

6.

Less shortening of the component, as compared to that in flash or butt welding.

7.

There is no flux, gas, filler metal or slag present to cause imperfections in welds.

2.8) Applications of friction welding:1. Commercial parts:Many commercial parts are candidates for inertia welding due to the fact that the weld is
accomplished quickly and with minimum clean-up. The fact that the weld is at 100% strength, it
provides a stronger part than traditional welds. Suggested uses are, but not limited to: Tool
extensions, tool blanks, baseball bats, golf putters, air cylinders, munitions, fasteners, oil pipe and
waterpipe fittings, bicycle parts, medical equipment, marine equipment, electrical equipment,
photographic and sound equipment.

34

Fig: 2.8.1, Flange

2. Aerospace:
Full strength inertia welded parts are used in a wide variety of aerospace
applications.Items such as turbine wheels and shafts, pressure vessels, landing gear struts,
ballscrew assemblies, actuator components, gear blanks and gear assemblies are just a few
examples. Many Interface Welding parts have been used in satellites, space shuttles Hubble
Telescope.

Fig: 2.8.2, Aerospace Part

35

3. Hydraulic:
Hydraulic cylinders and valves are prime candidates for inertia welding. The cylinders
can be completely machined and the caps can be weld on afterwards providing for cost reductions
and minimal inventory requirements. For irregular shapes, the cylinder can be welded to a larger
piece of material to reduce cost and machine time. This process also lends itself to the pistons and
shaft weldments as well as side ports.

Fig: 2.8.3, Couplings

4. Automotive:
In many automotive applications it is necessary to use different stress loads on various
types of materials. In some cases the requirement of two types of metal on one part such as a
valve serves the requirement of "putting the right metal in the right place". Using a stronger
material for the stem and a heat tolerant material for the head. Other applications include,
36

differential spools, drive shafts, axles, front wheel drive shaft joints, wheels and rims, certain
camshaft and crankshaft applications. Depending on the application, the parts can be welded in a
pre-weld configuration or a semi-finished condition.

Fig: 2.8.4, IC-Engine Valves

5. Bi-metal:
Since 1966, Friction Welding, a solid state metal joining process, has been successfully
used to join a wide range of metals that are commonly considered not weldable. These full
strength welds, when helium leak tested, will exceed requirements of 10 -9, showing less leakage
at the joint than thru parent metal. Many discriminating companies use bi-metal weldments
produced by Interface Welding, which was founded in 1967.
Product applications range from electrical connectors, vacuum and pressure systems,
satellite heat pipes and pressure storage systems, turbine engine components, cryogenic fittings,
37

glass to metal seals and numerous other critical products. This technology is being expanded
daily in our facility. Friction welders are versatile enough to join a wide range of part shapes,
materials, and weld sizes. Applications typically friction welded include aircraft and aerospace
components, cutting tools, agricultural machinery, automotive parts, oil field pieces, waste
canisters, military equipment, spindle blanks and bimetallic materials.

Fig: 2.8.5, Friction Welding Products

6. Agricultural field:
Friction welding is used extensively in the agricultural and trucking industries because
the welds are of forged quality, with a 100% butt joint weld throughout the contact area. This
bond is strong enough to handle the high stress and torque required of heavy machinery
components.

38

7. Drill rods:
Manufactured in house, Colcrete Eurodrill can to provide DTH Friction Welded Drill Tube
and Rotary Drilling Friction Welded Drill Rods with A.P.I. connections. Drill Pipe up to 139.7
mm (5 ") diameter friction welded in house. Drill Pipe is manufactured up to 406 mm (16")
diameter and 9 metre effective length. All tool joints are nitrided for extra wear resistance.

Fig:2.8.6, Drill Rod

39

Fig: 2.8.7, Universal Joint Yoke

Fig: 2.8.8, Friction Welding Products

2.9) Quality and environmental aspects:-

40

Today, any new industrial process needs to be thoroughly assessed regarding its
impact on the environment. Careful consideration of HSE (Health, Safety and Environment)
issues at the workplace is of crucial importance to any company currently investing in new
processes. It is also increasingly common for manufacturers to monitor a products environmental
impact throughout its life cycle.
2.9.1) Less weld-seam preparation:Butt, overlap and blind welds are the main weld applications for the FSW
process. To prepare the right bead configuration, workpieces featuring greater wall thicknesses
often require a special cutting or milling process.

2.9.2) Fewer resources:The FSW Process needs no shielding gas and therefore no gas supply or plant
investment such as pressure tanks, pipe fittings and gas regulators, as long as it is applied to low
melting temperature materials such as aluminium. No need for consumables, eliminating the need
for their storage and transport inside the production area, and avoiding the need for their
production elsewhere.

An FSW unit means less investment in the workplace. No need to protect

workers/users against UV or IR radiation. The FSW process generates no smoke and, unlike arc
welding processes (especially with aluminium), an exhaust system is not necessary.
2.9.3) Noise, an underestimated health threat:The commonest welding processes for aluminium are the MIG-pulse or TIG squarewave techniques. When used for workpieces of medium thickness, both processes require a lot of
41

energy. Furthermore, the pulse or square-wave frequencies make noise protection for the worker
a must, although this is often ignored. Due to its electric spindle drive and hydraulic unit for
axial pressure, an FSW unit generates consistently less noise, comparable to a standard milling
machine
2.9.4) Energy saving FSW process:When considering energy consumption, three factors must be assessed: how much
energy is required to perform the weld, what is the total energy required to operate the machinery
and ancillary equipment, and how much energy is required for post treatment (grinding and
cleaning). Generally, FSW demands less energy input to the weld than MIG and TIG, but more
than laser welding. Total energy input depends on the size of the equipment being used and the
thickness of the joint, depending on whether single-pass or multipass welding is used. FSW is
always single pass, offering the greatest energy savings at higher wall thicknesses.
2.9.5) Less post-treatment and impact on the environment:With most other welding processes, the weld requires weld and root reinforcement.
In the latter case, this means grinding, with a negative impact on the workplace environment, as
well as increased energy consumption and additional investment in equipment.
2.10) Various friction welding machines:NCT is a friction welder and machine tool builder. We have met the varied
needs of our customers in the USA, Canada, Mexico and South America with custom designed
solutions since 1983. NCT is ready to retrofit or repair all existing machine tools, and design and
deliver welders or machine tools to meet your needs. Equipment leasing with complete technical
support and service is also available.
10 Ton Machine for Welding Axle housing For Toyota

42

15 Ton Machine to Weld Drills, Reamers and IC Engine Valves

43

15 Ton Machine for welding axle housing of Trucks

6 Ton Vertical friction Welding machine to weld IC Engine valve

44

2.10) Weldable Material Combinations:-

45

This chart shows only a portion of known joinable materials & combinations and does not imply
that materials not listed are not joinable

46

CHAPTER 3

FABRICATION OF FRICTION
STIR WELDING

3.1) Introduction:-

47

Friction Stir Welding (FSW) was invented by Wayne Thomas at TWI (The Welding
Institute), and the first patent applications were filed in the UK in December 1991. Initially, the
process was regarded as a laboratory curiosity, but it soon became clear that FSW offers
numerous benefits in the fabrication of aluminium products.
In FSW, a cylindrical shouldered tool with a profiled pin is rotated and plunged into the
joint area between two pieces of sheet or plate material. The parts have to be securely clamped to
prevent the joint faces from being forced apart. Frictional heat between the wear resistant welding
tool and the work pieces causes the latter to soften without reaching melting point, allowing the
tool to traverse along the weld line. The plasticised material, transferred to the trailing edge of the
tool pin, is forged through intimate contact with the tool shoulder and pin profile. On cooling, a
solid phase bond is created between the work pieces.
Friction Stir Welding can be used to join aluminium sheets and plates without filler wire
or shielding gas. Material thicknesses ranging from 0.5 to 65 mm can be welded from one side at
full penetration, without porosity or internal voids. In terms of materials, the focus has
traditionally been on non-ferrous alloys, but recent advances have challenged this assumption,
enabling FSW to be applied to a broad range of materials.
To assure high repeatability and quality when using FSW, the equipment must possess
certain features. Most simple welds can be performed with a conventional CNC machine, but as
material thickness increases and arc-time is extended, purpose-built FSW equipment becomes
essential.
The quality of an FSW joint is always superior to conventional fusion-welded joints. A
number of properties support this claim, including FSWs superior fatigue characteristics. Figure
3 clearly demonstrates the improved performance of FSW compared to a MIG-welded joint on
the selected base material.

48

Fig: 3.1.1, Friction-Stir Welding Process

3.2) Components of FSW Model:- (Geometrical models)

The Main Components of Working Model of Friction-Stir Welding that we designed in
Solid Works Are:
1)
2)
3)
4)
5)
6)

Probe
Slider
Motor
Vertical Supports
Long Screw Guide with handle
C-Shaped Support

3.2.1) Probe:The Probe is the important component of FSW. There are different types of Probes
depending on Operating load and Hardness of the material. Among them Tapered-Flute screw pin
is the important one.
The Different models of Probe are:
1) Straight-Cylindrical-Tapered-Threaded-Tool
49

2) Straight-Cylindrical-Tapered-Tool
3) Straight-Cylindrical-Threaded-Tool
4) Straight-Cylindrical-Tool
5) Straight-Sqaure-Tool

1) Straight-Cylindrical-Tapered-Threaded-Tool:This Tool is of Cylindrical shape which is step turned and the bottom of the
tool has a tapered shaped cylinder with screw threads for easy penetration and for increasing the
material flow. This tool is mainly used for Hard materials.

2) Straight-Cylindrical-Tapered-Tool:50

This is same as above but it has no screw threads on the Tapered part of the tool.
This tool is used for smooth materials such as aluminium etc.

3) Straight-Cylindrical-Threaded-Tool:This tool has a cylindrical probe at the bottom of the stem which is threaded and
this also used for hard materials.

4) Straight-Cylindrical-Tool:51

This tool is same as above but the bottom cylindrical probe part is not Threaded.
This tool is used for soft materials.

5) Straight-Sqaure-Tool:This tool has a square shaped probe at the bottom of the stem. This tool is used for
welding purpose of high durable and heavy materials.

3.2.2) Slider:52

The Slider is the main supporting part of the machine or model which gives support for
the C-shaped structure we are using in our model. The Slider bears all the loads of motor, Cshape and tool.
Dimensions:Length----- 2000mm
Breadth-----600mm
Height------- 125mm
Slider part----- 2000X150mm in middle
Gap---------- 50mm

3.2.3) Motor:-

53

The motor is the main component which results in developing of Friction Heat between
the welding surfaces. Different capacity motors are used depending upon the hardness, Thickness
of the materials to be weld.

3.2.4) Vertical Supports:The Vertical supports are used for supporting the Long Screw guide which is used
for Horizontal movement of the tool and they are also used for Supporting the support rod for the
C-shape structure.

3.2.5) Long Screw Guide With Handle:54

This is the main component of FSW which is used for the horizontal movement of
the tool and which also takes some fraction of weight of the C-shape structure. This component
has a long cylindrical rod which has screw threads on it and to which a handle is attached to one
side of the rod.

3.2.6) C-Shaped Support:C-Shaped support is the core component of FSW machine which supports vertical
support to which motor is attached and through which screw-threaded rod passes which helps in
horizontal movement of the tool. It is of C-shape which has Two holes(side view) one has
internal threads and one is plane hole and Four holes on top through which plane rods passes
which supports the vertical slider to which motor is attached.

55

3.3) Assembly of FSW Model:This is a very simple Model of FSW which is used to friction weld small sheets. The
models in the below pictures and the real-time model is different. The models below show Iron
supports but we used supports made of Musk wood which is easy to cut and the wood is stiff and
very strong.
On the base made also from Musk wood we nailed the two vertical supports in place
and drilled Two Hole of 21 mm Diameter each.at a distance of 6.5cm From top of the support and
hole to hole distance is 3.5cm.
The C-Shape is made of Iron. Which we did by taking a long rectangular bar of length
32cm and is cut equally from a distance of 8cm from each side by using a Gas- Welding and later
we welded the Two halves at 90 Degrees angle and cooled immediately for strengthening the Cshape Hardness.
We made use of a Rod of 21 mm Diameter which is Threaded already and according to
the setup under a cutting machine cut to required size and to its other we welded a handle after its
insertion into the wooden supports in the mean time Holes are drilled into the C-shape of the

56

Diameter of the threaded support and plane rod support below it. And also holes for the Tool
support on the top of the shorter arm.
The Rods are inserted into the C-shape and after it alignment is checked and after it
tool supports also placed and main tool slider with springs is attached to the supports and to its
end a support for the motor of capacity (1000 RPM) is also welded and the probe is attached with
a screw to the end of the shank of the motor. With the help of the supports from the wood vertical
supports placed a wooden tool-bed for placing the work piece. With this Assembly is complete.

Fig:3.1.2, FSW Solid Works Model

57

Fig: 3.1.6, FSW Model

58

3.4) Project Pictures:-

Fig: 3.1.3, FSW Model

59

Fig: 3.1.5, FSW Front View

60

CHAPTER 4

Geometric Modelling
And Analysis Of FSW Probe
61

4.1) Introduction:Welding tool design is critical in FSW. Optimising tool geometry to produce more
heat or achieve more efficient stirring offers two main benefits: improved breaking and mixing
of the oxide layer and more efficient heat generation, yielding higher welding speeds and, of
course, enhanced quality. The simplest tool can be machined from an M20 bolt with very little
effort. It has proved feasible to weld thin aluminium plates, even with tooling as simple as this,
although at very slow welding speeds. However, tool materials should feature relatively high
hardness at elevated temperatures, and should retain this hardness for an extended period. The
combination of tool material and base material is therefore always crucial to the tools operational
lifetime.
Material flow behaviour is one of the most important key factors to influence the
quality of FSW weld, which has led many researchers to investigate material flow by means of
experimental methods or numerical simulation methods experimentally examined material flow
behaviour in FSW using a marker material technique and provided a semi-quantitative view of
the material transport in the weld zone. showed by X-ray images that material flow of the
implanted steel shot in the advancing side is bigger than that in the retreating side by the software
FLUENT showed that the tool with one-spiral-flute shoulder is better than the tool with a
concentric-circles-flute shoulder by coupled. In the practical welding process, the root flaws are
the most common defects, which may appear near the bottom of the weld and are bad for the
quality of weld. In this manuscript, two kinds of tool pin with special geometry are put forward,
and material flow behaviour during the FSW process is discussed by using the software ANSYS
FLUENT.

4.2) Design Principles:The simple pin-shaped, non-profiled tool creates frictional heat and is very useful if
enough downforce can be applied. Unfortunately, the oxide-layer breaking characteristics are not
very good, and as material thickness is increased, welding heat at the lower part of the joint may
be insufficient. With parameter adjustment and tool geometry optimisation, the oxide-layer could
be broken more effectively. The need to generate more frictional heat and break the oxide-layer
62

more effectively has been a driving force in tool development for light-metals. In Figure below
different pin-tools are displayed showing differences in shape, size and geometric features, to
match the needs of specific applications. Tool materials for mild and stainless steel have been
added to the list. Figure below illustrates some standard tools trademarked by TWI (The Welding
Institute). Triflute MX has proven to be a very capable multipurpose tool for welding all
aluminium alloys.

Fig.4.2.1,Pin-Tool Geometrics for FSW

Fig.4.2.2, Some of the basic tool shapes for friction stir welding.
Tools for Steel:63

To apply FSW in steel or other high-temperature materials, the difficulty is mainly

associated with finding proper tool material; a material that can withstand the high temperatures
that are experienced during the process. Resistance to wear (durability) is one important aspect,
especially as many of the intended applications are considered critical; hence there can be no
traces of the tool left in the seam. One of the most promising tool materials so far is the so called
PCBN.

Fig.4.2.3, FSW Tools

4.3) Geometrical Model of Probe:64

During the FSW process, the welding material is in a plastic state. The material
must be stirred and then mixed enough to get a sound FSW weld. Therefore, it is necessary for
the material to undergo the violent flow. In fact, many defects of FSW related to material flow
include cavity, kissing bond, root flaws, and so on. The rotational tool is made up of a shoulder
and a rotational pin.
During the FSW process, the tip of the rotational pin is inside the welding material
in order to avoid contact between the tool and the backing plate and then the damage of the tool
or backing plate. Generally speaking, the distance between the tip of pin and the bottom of the
welding work piece is 0.1~0.2 mm. However, the practical distance between the tip of pin and the
bottom of the work piece is longer or shorter than 0.1~0.2 mm, which results in the change of
work piece thickness or the change of plunging depth of tool. The longer distance may result in
the appearance of root flaws because of the lack of enough material flow.

Fig:4.3.1, FSW Multi-angle Machine

65

(a) The conventional tool used

(b) The tool with half-screw pin used in

in numerical simulation

numerical simulation

The above are the tools we Designed in solid works figure (a) The conventional tool used in
numerical simulation Figure (b) The tool with half-screw pin used in numerical simulation On the
above two models material flow analysis is done using ANSYS-FLUENT. In Figure 1a, the
diameter of the shoulder is 17 mm and the width of the flute in the shoulder is 0.5 mm. The
length of the rotational pin is 2.8 mm, the pin is tapered from 9 mm at the pin bottom to 6 mm at
the pin tip and the width of the flute is 0.4 mm. In Figure 1b, the width of the flute of the pin is
0.4 mm. In Figure 1c, the maximum width of the flute of the pin is 0.4 mm and the minimum
width is 0.2 mm

4.4) Analysis of Material Flow Properties of the Probe:How to improve material flow behaviour has been attracting researchers
attention since FSW was invented in 1991.In our project we investigated the effect of shoulder
geometry and pin geometry on material flow velocity and then suggested that the flute geometry
of the tool is the most important factor to be designed. For the two rotational tools above have the
dimensions of shoulder, diameters of pin bottom, diameters of pin tip and lengths of pin are all
the same.
The Analysis on Material flow is done on the above two geometric models of the
probe and the Steps involved are

66

4.4.1) Mesh Generation:Figure below shows mesh generation of the work piece used to simulate while the
corresponding tool is the tool in above figures. It is well known that material near the rotational
tool flows violently during the FSW process, so we are able to use the dimensions of mesh near
the rotational tool in order to describe material flow behaviour in detail.

Fig:4.3.1, Work Piece Mesh Profile

4.4.2) Material Parameters:In this Analysis, Ti6Al4V titanium alloy is chosen as investigated subject. The
specific heat, the thermal conductivity and the density of Ti6Al4V alloy are 879 J/KgK, 15.91
W/mK and 4.45 g/cm3, respectively. The RNG k- model is used in this study and the material is
supposed to be fused liquid. The viscosity of Ti6Al4V alloy is unchanged and the value is 5.3
mPas.
4.4.3) Boundary Conditions:During the process of numerical simulation, the plastic material is considered as the
fluid, which flows into the computational region by the inlet and flows out of the outlet. The
surface of workpiece, the bottom of workpiece, the advancing side, the retreating side, the inlet
side and the outlet side are all considered as the moving walls. The speed of moving walls is
equal to the welding speed of 75 mm/min and the moving direction is opposite to the welding

67

direction. The elements used to represent the rotational tool are considered as the rotational wall
while the rotational velocity of 250 r/min and the rotational direction of the wall are both the
same as those of the tool. Moreover, the non-slip boundary condition is used to describe the
relation between the material contacting the tool and the rotational tool.
4.4.4) Observations:In order to research material flow field during FSW, three representative positions are
considered near the surface, in the middle of work piece, between the pin tip and the bottom of
the work piece. Figure 3 shows three researched sections, which are parallel to the surface of the
work piece and are respectively called sections a, b and c.

Fig: 4.3.2, Machining View Diagram

(i)

Material Flow Behavior of the Tool with Tapered-Flute Pin during FSW :The flow velocity of the material in contact with the tool is the same as the linear

velocity of the contact position of tool The flow of material in contact with the rotational tool
makes the nearby material flow. However, the flow velocity of nearby material is lower than that
of the material in contact with the tool in terms of the effect of viscosity of material. Therefore,
material flow velocity reduces with the increase of distance away from the rotational axis.
The flow direction of material in contact with the shoulder is the same as the
rotational direction of the tool. The flow direction of material in contact with the pin can be

68

divided into two parts. One is the same as the rotational direction of the tool and the other is
downward in the vertical direction.
Moreover, for material along the vertical direction, the flow velocity and the region
under high flow velocity both decrease with the increase of distance away from the work piece
surface, which results from the change of the rotational pin diameter. The flow velocity of the
material in the region between the pin tip and the work piece bottom is relatively small, which
may result in root flaws.

Fig(4.4.4-1a)- 3D material flow field by the tool with the tapered-flute pin

69

Fig (4.4.4-1b) Flow Field at Section (a) Parallel to Work Piece

Fig 4.4.4-1c Flow Field at Section (b)

70

Fig 4.4.4-1d Flow Field at Section (c)

(ii)

Effect of Flute Geometry on Material Flow:The figures below show material flow velocity fields by the conventional tool

and the tool with the half-screw pin at section b and section c.

Flow field at section (b) by conventional tool

71

Flow field at section (b) by the tool with the half-screw pin.

Flow field at section (c) by the conventional tool

72

Flow field at section c by the tool with the half-screw pin.

From Figures 4.4.4 (1a to 1d), it is also concluded that the flute of the tool can
greatly increase the flow Velocity of the material. Therefore, the reasonable design of the flute
geometry is very important to the rotational tool of FSW. After fluid flows into the flute, the flow
velocity of the material reduces with the increase of flow length.
Therefore, the short flute is better than the long flute in terms of increasing the flow
velocity of material, which is the reason why the tool with the half-screw pin is designed in order
to avoid root flaws. From Figures 4.4.4 (2a to 2d), it is seen that the tool with half-screw pin can
improve the flow velocity of the material not only near the bottom of workpiece but also in the
middle of workpiece. Moreover, From Figures 4.4.4-1d and 2c and2d, it is seen that material flow
velocity in the retreating side is higher than that in the advancing side.
As is reported, the material during FSW process can be considered as the
incompressible fluid and the flow behavior follows the continuity law of the fluid, whose
expression is shown in Equation (1):
73

V1 A1 = V2 A2 = Constant. Eq (1)
where V is the flow velocity of the material and A is the area of channel cross section.
The subscript 1 and 2 mean the cross section 1 and cross section 2, respectively.
From Equation (1), it is known that the flow velocity of material during FSW is
inversely proportional to the area of flute. Therefore, a small flute width is beneficial for
increasing the flow velocity of the material, which is the reason why the flow velocity of material
at section c by the tool with the tapered-flute pin is higher than that by the conventional tool.

74

CHAPTER 5

RESULTS AND CONCLUSIONS

75

5.1) Results:The Assembly of Friction-Stir Welding model is done and is fitted with 1000 RPM motor
and 12V Battery its tested on aluminium sheet of 0.2 mm Thick ness and as it is a simple DC
motor which is not Side-shaft it cant take high loads so the welding is partially done and it can
be improved with a high load and by using a side-shaft DC motor.
5.2) Future Prospects:From the Results above FSW machine model if its to be built into full scale machine
then the following Factors should be considered.
1) Motor with High load-bearing capacity
2) Probe tip made of chrome-steel
3) Probe fitted to Gearing system which is geared to motor
4) Half-Screw Flute Tapered Should be profile of probe Tip for better material-flow while
welding.
5) There should be perfect alignment between the vertical supports, motor, tool.
6) Using a Motor controller can help in achieving Perfect Bead and the timing between
Plastic Deformation and Fusion of the two work pieces surface.
7) By using Timing Gear between Threaded Rod and gear box used for horizontal movement
of tool can help in achieving perfect Weld.
Conclusions of Analysis:-

FSW is here to stay. The process has demonstrated its capabilities and been
approved as a novel method for joining aluminium and other metals. FSW is opening up totally
new areas of welding daily. The welding process improves existing structural properties and
leaves the weld cold. In some cases, if proper care is taken, weld properties equal those of the
base material. In conclusion, the results of the present study demonstrate that the geometry of the
flute of a rotational tool during the friction stir welding process greatly influences the material
76

flow behaviour. The tool with half-screw pin and the tool with tapered-flute pin both obviously
increase material flow velocity near the bottom of the work piece and are both beneficial in
avoiding root flaws.
References:1) Design of Friction Stir Welding Tool for Avoiding Root Flaws an article by Jingwei Xing,
Yumei Yue, Yinan Ma, Liguo Zhang and Shuangsheng Gao of Faculty of Aerospace
Engineering, Shenyang Aerospace University, Shenyang 110136, China
2) International Journal of Emerging Technology and Advanced Engineering, Friction-Stir
welding, Volume 4, Issue 3, April 2003.
3) FSW Technical Hand book by ESAB.
4) Study of FSW By Ranjhan Sahoo, Graduate from IIT Roorke.
5) Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter
13
6) Pin Tool Geometry Effects in Friction Stir Welding By J.A. Querin, H.A. Rubisoff, J.A.
Schneider, Department of Mechanical Engineering, Mississippi State University.
7) Friction Stir Welding/Processing Tool Materials and Selection By Kudzanayi Chiteka
Production engineering, Delhi Technological University, India.
8) friction stir welding tools By R. Rai, A. De, H. K. D. H. Bhadeshia and T. DebRoy.
9) Fundamentals of Modern Manufacturing ,Materials ,Processes ,and Systems" ,4th edition,
JOHN WILEY & SONS, INC.,2010
10) Valery Marinov, Manufacturing Technology, Solid-state Welding, Chapter 12 page :132.

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78