Friction-stir Welding Assignment

A report submitted in fulfillment of the requirements for the Course IE222

Department of Mechatronics engineering,
German Jordanian University, Madaba,
Second semester 2014

Laith Salameen 2011102039

Salem Al-Masa'afeh 2011102034
Saif Hawamdeh 2010105012

Instructors: Dr. Ilyas Khader

Abstract
Friction stir welding (FSW) is a relatively new joining which is advantageous for joining and has been
implemented commercially around the world in several different industries. It eliminate casting
defects and refine microstructures, thereby improving strength and ductility, increase resistance to
corrosion and fatigue, enhance deformability, and improve other properties. During this paper we also
present an improved form of FSW invented by Mazda to be implemented in structural design of car
components.

Table of Contents
Abstract ................................................................................................................................................... 1
Historical Background ............................................................................................................................. 1
Introduction ............................................................................................................................................. 2
Advantages and Disadvantages ............................................................................................................... 3
Application found in method of processing metal members ................................................................... 4
Conclusion ............................................................................................................................................... 7
References ............................................................................................................................................... 8
Bibliography ............................................................................................................................................ 8

Historical Background
Quick overview and origins of Friction-stir Welding
Friction stir welding is a fairly new welding process, that was invented by Wayne Thomas at The
Welding Institute UK in December 1991; by which later TWI (The Welding Institute) obtained
patents1 for worldwide. The first patents was for the process, while the second patent included key
innovations and enhancements such as on the movement of material and the tool tips2.
Furthermore when FSW (friction-stir welding) was first invented, it overcame many of the problems
that were found in traditional welding techniques and quickly became the primary option for
manufacturing light weight structures and bodies3 and is considered a green process with no fumes or
arc light emitted in addition to that no shielding gas is required or welding wire consumed.

Patentsinclude:EP0615480,EP0752926,US5813592&others(Howeverrecentlyexpired)
http://www.twiglobal.com/services/intellectualpropertylicensing/frictionstirwelding/intellectual
propertyrights/
3
http://www.twiglobal.com/technologies/weldingsurfaceengineeringandmaterialprocessing/frictionstir
welding/
2

Introduction
Basic principle of operation
FSW is a solid state joining process which operates by having a FSW tool [see Fig.1 for the tool tip]
plunged with a very high compressive force in between two work pieces, however not all the tool and
its components are drilled in rather just only the probe is. This requires heavy machinery and tooling
to ensure the two work pieces are held in place.
Once the hole is made and reaches the required depth, the tool starts spinning at a specified rate, which
in turn induces frictional heat.
This frictional heat creates a temperature increase at the spot where the probe is rotating and this spot
is known as the stir zone. Note however that although the temperature rises, it never exceeds the
melting point of the material being welded.4

Figure 15
As the heat rises the material softens. This softening in addition to the horizontal movement of the
tool; mixes the material to the rear, while the force from the shoulder induces plane stresses ensuring
that no material is removed out the work pieces but rather mixed throughout.
Finally once the process is completed the probe is removed along with the tool and the temperature
starts going down allowing the material to go through recrystallization.
Note that the hole caused by the pin at the end of the process will remain permanently unless filled in
by refining processes and machining.

4
5

Wikipedia
http://www.twiglobal.com/EasysiteWeb/getresource.axd?AssetID=4619&type=full&servicetype=Inline

Figure 26 shows the progress of the tool throughout the joint as the tool propagates

Advantages and Disadvantages

Advantages of the System
As stated earlier, that the process is a green process with no fumes or arc light emitted and that no
shielding gas is required or welding wire consumed, as well as that the common problems found in
traditional welding processes such as porosity, solute redistribution, solidification and liquid cracking7
are not associated with FSW. This is due to the fact that the process is done below the melting
temperature of the material in addition to having no additional material being added.
This furthermore leads to excellent mechanical properties, and adds a good weld appearance with
minimal thickness difference along the weld. This in turn reduces the expenses related to machining
and other various post welding processes.

Known recurring problems

With all complex welding processes (such as spot welding and stir welding) there is a need for very
large and heavy machinery required to perform them and withstand the high forces induced. This
makes it very difficult to change or modify any of the welding process since it is not a flexible
operationthus you will require a full revamp and modification to tools, machines and also recreate
new models and calculations based on the new modification. Furthermore the permanent hole left in
the final weld may be a cause of concern, as it creates a point where any stresses may gather.

6
7

http://www.fanucrobotics.com
Wikipedia

Application found in method of processing metal members8

Introduction
The patent paper outlines the method of joining two overlapping metal members by FSW using
multiple rotating tools as shown in Figure 4. [Note W1 and W2 are the metal members while 3a and
5a are the probes]. This process is used in in processing metal members such as aluminium alloy
castings and plate materials.
However unlike typical FSW techniques the patent claims to ensure the final result does not include
the post weld hole left behind, rather resulting in a concave portion to form on the tip portion of the
top member [see figure 5] and in turn constructs a stronger member to member junctions without
causing thermal distortion.

Figure 4

Figure 5 shows the end result of said process

MAZDAMOTORCORPORATION(WorldwidePatentNo.WO2001083153A1,Nov8,2001)
NOTETHATALLIMAGESANDREFRENCESFROMHEREONOUTWEREEXTRACTEDFROMTHISPATENT

In addition to that a successful join of the lapped metals is ensured when the material thicknesses are
large, while reducing the joining time.

Materials tested
Tests were conducted on multiple plates consisting of Al, Al-Zn, Fe-Zn and Fe plates.

Tools used
The two probes used had a very distinct feature than that found in typical FSW probes, which is that
they included a hollow concave dip [see figure 6], which resulted in less material to burr9 out of the
surface.
In addition to that each probe had different dimensions, where the bottom (15mm) one had a larger
diameter then the one on top (10mm). Moreover
the top and bottom were titled at an angle of 1
degree backwards.
Notice how the mixing throughout the concave dip
is done. Imagine a second probe on the bottom
plate in addition to the tilt induced.
All these variables coupled together results in the
final microstructure of that shown in FIG.7.

Figure 6

Figure 7

Burr:deformationofmetalwhereinaraisededgeformsonametalpartwhichhasbeenmachined

Alloy diffusion within the microstructure

It starts off with three distinct metal layers

With time and heat, metals diffuse forming new alloys

Furthermore diffusion and alloying occurs

Finally the resultant mixture contained an Al-Zn-Fe alloy

Test results based on pressing force, time and number of revolutions

Testing was performed using various different speeds, forces and revolutions as shown below

Pressing force and rpm10 constant

rpm constant, pressing force increasing linearly

10

Rpmconstantsetat1000rpm

Pulsating rpm, pressing force constant

Pulsating rpm, pressing force increasing linearly

Results
Decreasing the rpm periodically promoted the breaking of the oxide film on the aluminium alloy
member and decreasing the number of revolutions causes joining to take a longer time, therefore, is
not preferable.
When the pressing force decreased it ended up causing an unsatisfactory plastic flow, thereby making
it impossible to obtain satisfactory joining strength.
As for the relationship between the number of revolutions and the pressing force, the pressing force
must be increased as the metal structure is softened.

Conclusion
Friction stir welding process as we have reviewed, analyzed and presented. The metallurgical
environmental and energy benefits of the process compared to the conventional arc welding processes
had also been presented. The process is increasingly becoming popular and is being embraced by
many industries. It can be concluded that FSW is a green technology.
Also, friction stir welding is now a mature and robust process, which is becoming increasingly well
established in the fabrication of critical components. The qualities making the process attractive
include reduced cost, minimal repair requirement, good properties and total automation leading to a
high level of consistency. At the present time, FSW can compete with other welding processes for
quality of welds and performance. It should be noted that FSW is still relatively new, and has been in
commercial production for less than 15 years. Nevertheless, progress has been significant, and further
improvements and developments can be expected.

References
Wikipedia,
Website URL: http://en.wikipedia.org/wiki/Friction_stir_welding
The welding institute,
Website URL: http://www.twi-global.com
Fanucrobotics,

Website URL: http://www.fanucrobotics.com

Bibliography
Gendoh Toshiyuki, N. S. (Nov 8, 2001). Worldwide Patent No. WO2001083153 A1.