09/12/2016 FrictionstirweldingWikipedia

Frictionstirwelding
FromWikipedia,thefreeencyclopedia

Frictionstirwelding(FSW)isasolidstatejoiningprocessthatusesa
nonconsumabletooltojointwofacingworkpieceswithoutmeltingthe
workpiecematerial.Heatisgeneratedbyfrictionbetweentherotatingtool
andtheworkpiecematerial,whichleadstoasoftenedregionneartheFSW
tool.Whilethetoolistraversedalongthejointline,itmechanically
intermixesthetwopiecesofmetal,andforgesthehotandsoftenedmetal
bythemechanicalpressure,whichisappliedbythetool,muchlikejoining
clay,ordough.Itisprimarilyusedonwroughtorextrudedaluminiumand
particularlyforstructureswhichneedveryhighweldstrength.
Closeupviewofafrictionstirweld
ItwasinventedandexperimentallyprovenatTheWeldingInstitute(TWI) tacktool.
intheUKinDecember1991.TWIheldpatentsontheprocess,thefirst
beingthemostdescriptive.[1]

Contents
1 Principleofoperation
2 Microstructuralfeatures
3 Advantagesandlimitations
4 Importantweldingparameters Thebulkheadandnoseconeofthe
4.1 Tooldesign Orionspacecraftarejoinedusing
4.2 Toolrotationandtraversespeeds frictionstirwelding.
4.3 Tooltiltandplungedepth
5 Weldingforces
6 Flowofmaterial
7 Generationandflowofheat
8 Applications
8.1 Shipbuildingandoffshore
8.2 Aerospace
8.3 Automotive
8.4 Railways
8.5 Fabrication
8.6 Robotics Jointdesigns
8.7 Personalcomputers
9 Seealso
10 References
11 Externallinks

Principleofoperation
Arotatingcylindricaltoolwithaprofiledprobeisfedintoabuttjointbetweentwoclampedworkpieces,untilthe
shoulder,whichhasalargerdiameterthanthepin,touchesthesurfaceoftheworkpieces.Theprobeisslightly
shorterthanthewelddepthrequired,withthetoolshoulderridingatoptheworksurface.[2]Afterashortdwell
time,thetoolismovedforwardalongthejointlineatthepresetweldingspeed.

https://en.wikipedia.org/wiki/Friction_stir_welding 1/12
09/12/2016 FrictionstirweldingWikipedia

Frictionalheatisgeneratedbetweenthewearresistanttooland
theworkpieces.Thisheat,alongwiththatgeneratedbythe
mechanicalmixingprocessandtheadiabaticheatwithinthe
material,causethestirredmaterialstosoftenwithoutmelting.
Asthetoolismovedforward,aspecialprofileontheprobe
forcesplasticisedmaterialfromtheleadingfacetotherear,
wherethehighforcesassistinaforgedconsolidationofthe
weld.

Thisprocessofthetooltraversingalongtheweldlineina
plasticisedtubularshaftofmetalresultsinseveresolidstate
deformationinvolvingdynamicrecrystallizationofthebase SchematicdiagramoftheFSWprocess:(A)Two
discretemetalworkpiecesbuttedtogether,along
material.[3]
withthetool(withaprobe).

Microstructuralfeatures
ThesolidstatenatureoftheFSWprocess,combinedwithits
unusualtoolshapeandasymmetricspeedprofile,resultsina
highlycharacteristicmicrostructure.Themicrostructurecanbe
brokenupintothefollowingzones:

Thestirzone(alsonugget,dynamicallyrecrystallised
zone)isaregionofheavilydeformedmaterialthat
roughlycorrespondstothelocationofthepinduring
welding.Thegrainswithinthestirzoneareroughly
equiaxedandoftenanorderofmagnitudesmallerthan
thegrainsintheparentmaterial.[4]Auniquefeatureof (B)Theprogressofthetoolthroughthejoint,also
thestirzoneisthecommonoccurrenceofseveral showingtheweldzoneandtheregionaffectedby
concentricringswhichhasbeenreferredtoasan"onion thetoolshoulder.
[5]
ring"structure. Thepreciseoriginoftheseringshas
notbeenfirmlyestablished,althoughvariationsinparticlenumberdensity,grainsizeandtexturehaveall
beensuggested.
Theflowarmzoneisontheuppersurfaceoftheweldandconsistsofmaterialthatisdraggedbythe
shoulderfromtheretreatingsideoftheweld,aroundtherearofthetool,anddepositedontheadvancing
side.
Thethermomechanicallyaffectedzone(TMAZ)occursoneithersideofthestirzone.Inthisregionthe
strainandtemperaturearelowerandtheeffectofweldingonthemicrostructureiscorrespondinglysmaller.
Unlikethestirzonethemicrostructureisrecognizablythatoftheparentmaterial,albeitsignificantly
deformedandrotated.AlthoughthetermTMAZtechnicallyreferstotheentiredeformedregionitisoften
usedtodescribeanyregionnotalreadycoveredbythetermsstirzoneandflowarm.
Theheataffectedzone(HAZ)iscommontoallweldingprocesses.Asindicatedbythename,thisregionis
subjectedtoathermalcyclebutisnotdeformedduringwelding.Thetemperaturesarelowerthanthosein
theTMAZbutmaystillhaveasignificanteffectifthemicrostructureisthermallyunstable.Infact,inage
hardenedaluminiumalloysthisregioncommonlyexhibitsthepoorestmechanicalproperties.[6]

Advantagesandlimitations
ThesolidstatenatureofFSWleadstoseveraladvantagesoverfusionweldingmethodsasproblemsassociated
withcoolingfromtheliquidphaseareavoided.Issuessuchasporosity,soluteredistribution,solidification
crackingandliquationcrackingdonotariseduringFSW.Ingeneral,FSWhasbeenfoundtoproducealow
concentrationofdefectsandisverytolerantofvariationsinparametersandmaterials.
https://en.wikipedia.org/wiki/Friction_stir_welding 2/12
09/12/2016 FrictionstirweldingWikipedia

Nevertheless,FSWisassociatedwithanumberofuniquedefects,ifitisn'tdoneproperly.Insufficientweld
temperatures,duetolowrotationalspeedsorhightraversespeeds,forexample,meanthattheweldmaterialis
unabletoaccommodatetheextensivedeformationduringwelding.Thismayresultinlong,tunnellikedefects
runningalongtheweldwhichmayoccuronthesurfaceorsubsurface.Lowtemperaturesmayalsolimitthe
forgingactionofthetoolandsoreducethecontinuityofthebondbetweenthematerialfromeachsideoftheweld.
Thelightcontactbetweenthematerialhasgivenrisetothename"kissingbond".Thisdefectisparticularly
worryingsinceitisverydifficulttodetectusingnondestructivemethodssuchasXrayorultrasonictesting.Ifthe
pinisnotlongenoughorthetoolrisesoutoftheplatethentheinterfaceatthebottomoftheweldmaynotbe
disruptedandforgedbythetool,resultinginalackofpenetrationdefect.Thisisessentiallyanotchinthematerial
whichcanbeapotentialsourceoffatiguecracks.

AnumberofpotentialadvantagesofFSWoverconventionalfusionweldingprocesseshavebeenidentified:[7]

Goodmechanicalpropertiesintheasweldedcondition
Improvedsafetyduetotheabsenceoftoxicfumesorthespatterofmoltenmaterial.
NoconsumablesAthreadedpinmadeofconventionaltoolsteel,e.g.,hardenedH13,canweldover1km
(0.62mi)ofaluminium,andnofillerorgasshieldisrequiredforaluminium.
Easilyautomatedonsimplemillingmachineslowersetupcostsandlesstraining.
Canoperateinallpositions(horizontal,vertical,etc.),asthereisnoweldpool.
Generallygoodweldappearanceandminimalthicknessunder/overmatching,thusreducingtheneedfor
expensivemachiningafterwelding.
Canusethinnermaterialswithsamejointstrength.
Lowenvironmentalimpact.
Generalperformanceandcostbenefitsfromswitchingfromfusiontofriction.

However,somedisadvantagesoftheprocesshavebeenidentified:

Exitholeleftwhentooliswithdrawn.
Largedownforcesrequiredwithheavydutyclampingnecessarytoholdtheplatestogether.
Lessflexiblethanmanualandarcprocesses(difficultieswiththicknessvariationsandnonlinearwelds).
Oftenslowertraverseratethansomefusionweldingtechniques,althoughthismaybeoffsetiffewerwelding
passesarerequired.

Importantweldingparameters
Tooldesign

Thedesignofthetool[8]isacriticalfactorasagoodtoolcanimproveboth
thequalityoftheweldandthemaximumpossibleweldingspeed.

Itisdesirablethatthetoolmaterialbesufficientlystrong,tough,andhard
wearingattheweldingtemperature.Furtheritshouldhaveagood
oxidationresistanceandalowthermalconductivitytominimiseheatloss
andthermaldamagetothemachineryfurtherupthedrivetrain.Hot
workedtoolsteelsuchasAISIH13hasprovenperfectlyacceptablefor
weldingaluminiumalloyswithinthicknessrangesof0.550mm[9]but
moreadvancedtoolmaterialsarenecessaryformoredemanding
applicationssuchashighlyabrasivemetalmatrixcomposites[10]orhigher
Advancedfrictionstirweldingand
meltingpointmaterialssuchassteelortitanium. processingtoolsbyMegaStirshown
upsidedown

https://en.wikipedia.org/wiki/Friction_stir_welding 3/12
09/12/2016 FrictionstirweldingWikipedia

Improvementsintooldesignhavebeenshowntocausesubstantial
improvementsinproductivityandquality.TWIhasdevelopedtools
specificallydesignedtoincreasethepenetrationdepthandthusincreasing
theplatethicknessesthatcanbesuccessfullywelded.Anexampleisthe
"whorl"designthatusesataperedpinwithreentrantfeaturesoravariable
pitchthreadtoimprovethedownwardsflowofmaterial.Additionaldesigns
includetheTrifluteandTrivexseries.TheTriflutedesignhasacomplex
systemofthreetapering,threadedreentrantflutesthatappeartoincrease
materialmovementaroundthetool.TheTrivextoolsuseasimpler,non
cylindrical,pinandhavebeenfoundtoreducetheforcesactingonthetool
FSWoftwoUSIBOR1500high
duringwelding.
strengthsteelsheets
Themajorityoftoolshaveaconcaveshoulderprofilewhichactsasan
escapevolumeforthematerialdisplacedbythepin,preventsmaterialfromextrudingoutofthesidesofthe
shoulderandmaintainsdownwardspressureandhencegoodforgingofthematerialbehindthetool.TheTriflute
toolusesanalternativesystemwithaseriesofconcentricgroovesmachinedintothesurfacewhichareintendedto
produceadditionalmovementofmaterialintheupperlayersoftheweld.

Widespreadcommercialapplicationsoffrictionstirweldingprocessforsteelsandotherhardalloyssuchas
titaniumalloyswillrequirethedevelopmentofcosteffectiveanddurabletools.[11]Materialselection,designand
costareimportantconsiderationsinthesearchforcommerciallyusefultoolsfortheweldingofhardmaterials.
Workiscontinuingtobetterunderstandtheeffectsoftoolmaterial'scomposition,structure,propertiesand
geometryontheirperformance,durabilityandcost.[12]

Toolrotationandtraversespeeds

Therearetwotoolspeedstobeconsideredinfrictionstirweldinghowfastthetoolrotatesandhowquicklyit
traversesalongtheinterface.Thesetwoparametershaveconsiderableimportanceandmustbechosenwithcareto
ensureasuccessfulandefficientweldingcycle.Therelationshipbetweentherotationspeed,theweldingspeedand
theheatinputduringweldingiscomplexbut,ingeneral,itcanbesaidthatincreasingtherotationspeedor
decreasingthetraversespeedwillresultinahotterweld.Inordertoproduceasuccessfulwelditisnecessarythat
thematerialsurroundingthetoolishotenoughtoenabletheextensiveplasticflowrequiredandminimizethe
forcesactingonthetool.Ifthematerialistoocoldthenvoidsorotherflawsmaybepresentinthestirzoneandin
extremecasesthetoolmaybreak.

Excessivelyhighheatinput,ontheotherhandmaybedetrimentaltothefinalpropertiesoftheweld.Theoretically,
thiscouldevenresultindefectsduetotheliquationoflowmeltingpointphases(similartoliquationcrackingin
fusionwelds).Thesecompetingdemandsleadontotheconceptofa"processingwindow":therangeofprocessing
parametersviz.toolrotationandtraversespeed,thatwillproduceagoodqualityweld.[13]Withinthiswindowthe
resultingweldwillhaveasufficientlyhighheatinputtoensureadequatematerialplasticitybutnotsohighthatthe
weldpropertiesareexcessivelydeteriorated.

Tooltiltandplungedepth

Theplungedepthisdefinedasthedepthofthelowestpointoftheshoulderbelowthesurfaceoftheweldedplate
andhasbeenfoundtobeacriticalparameterforensuringweldquality.[14]Plungingtheshoulderbelowtheplate
surfaceincreasesthepressurebelowthetoolandhelpsensureadequateforgingofthematerialattherearofthe
tool.Tiltingthetoolby24degrees,suchthattherearofthetoolislowerthanthefront,hasbeenfoundtoassist
thisforgingprocess.Theplungedepthneedstobecorrectlyset,bothtoensurethenecessarydownwardpressureis
achievedandtoensurethatthetoolfullypenetratestheweld.Giventhehighloadsrequired,theweldingmachine

https://en.wikipedia.org/wiki/Friction_stir_welding 4/12
09/12/2016 FrictionstirweldingWikipedia

maydeflectandsoreducetheplungedepthcomparedtothenominal
setting,whichmayresultinflawsintheweld.Ontheotherhand,an
excessiveplungedepthmayresultinthepinrubbingonthebackingplate
surfaceorasignificantundermatchoftheweldthicknesscomparedtothe
basematerial.Variableloadweldershavebeendevelopedtoautomatically
compensateforchangesinthetooldisplacementwhileTWIhave
demonstratedarollersystemthatmaintainsthetoolpositionabovethe
weldplate.

Weldingforces Adrawingshowingtheplungedepth
andtiltofthetool.Thetoolis
movingtotheleft.
Duringweldinganumberofforceswillactonthetool:

Adownwardsforceisnecessarytomaintainthepositionofthetoolatorbelowthematerialsurface.Some
frictionstirweldingmachinesoperateunderloadcontrolbutinmanycasestheverticalpositionofthetoolis
presetandsotheloadwillvaryduringwelding.
Thetraverseforceactsparalleltothetoolmotionandispositiveinthetraversedirection.Sincethisforce
arisesasaresultoftheresistanceofthematerialtothemotionofthetoolitmightbeexpectedthatthisforce
willdecreaseasthetemperatureofthematerialaroundthetoolisincreased.
Thelateralforcemayactperpendiculartothetooltraversedirectionandisdefinedhereaspositivetowards
theadvancingsideoftheweld.
Torqueisrequiredtorotatethetool,theamountofwhichwilldependonthedownforceandfriction
coefficient(slidingfriction)and/ortheflowstrengthofthematerialinthesurroundingregion(stiction).

Inordertopreventtoolfractureandtominimizeexcessivewearandtearonthetoolandassociatedmachinery,the
weldingcycleismodifiedsothattheforcesactingonthetoolareaslowaspossible,andabruptchangesare
avoided.Inordertofindthebestcombinationofweldingparameters,itislikelythatacompromisemustbe
reached,sincetheconditionsthatfavourlowforces(e.g.highheatinput,lowtravelspeeds)maybeundesirable
fromthepointofviewofproductivityandweldproperties.

Flowofmaterial
Earlyworkonthemodeofmaterialflowaroundthetoolusedinsertsofadifferentalloy,whichhadadifferent
contrasttothenormalmaterialwhenviewedthroughamicroscope,inanefforttodeterminewherematerialwas
movedasthetoolpassed.[15][16]Thedatawasinterpretedasrepresentingaformofinsituextrusionwherethe
tool,backingplateandcoldbasematerialformthe"extrusionchamber"throughwhichthehot,plasticisedmaterial
isforced.Inthismodeltherotationofthetooldrawslittleornomaterialaroundthefrontoftheprobeinsteadthe
materialpartsinfrontofthepinandpassesdowneitherside.Afterthematerialhaspassedtheprobetheside
pressureexertedbythe"die"forcesthematerialbacktogetherandconsolidationofthejoinoccursastherearof
thetoolshoulderpassesoverheadandthelargedownforceforgesthematerial.

Morerecently,analternativetheoryhasbeenadvancedthatadvocatesconsiderablematerialmovementincertain
locations.[17]Thistheoryholdsthatsomematerialdoesrotatearoundtheprobe,foratleastonerotation,anditis
thismaterialmovementthatproducesthe"onionring"structureinthestirzone.Theresearchersuseda
combinationofthincopperstripinsertsanda"frozenpin"technique,wherethetoolisrapidlystoppedinplace.
Theysuggestedthatmaterialmotionoccursbytwoprocesses:

1.Materialontheadvancingsideofaweldentersintoazonethatrotatesandadvanceswiththeprofiledprobe.
Thismaterialwasveryhighlydeformedandsloughsoffbehindthepintoformarcshapedfeatureswhen
viewedfromabove(i.e.downthetoolaxis).Itwasnotedthatthecopperenteredtherotationalzonearound

https://en.wikipedia.org/wiki/Friction_stir_welding 5/12
09/12/2016 FrictionstirweldingWikipedia

thepin,whereitwasbrokenupintofragments.Thesefragmentswereonlyfoundinthearcshapedfeatures
ofmaterialbehindthetool.
2.Thelightermaterialcamefromtheretreatingsideinfrontofthepinandwasdraggedaroundtotherearof
thetoolandfilledinthegapsbetweenthearcsofadvancingsidematerial.Thismaterialdidnotrotate
aroundthepinandthelowerlevelofdeformationresultedinalargergrainsize.

Theprimaryadvantageofthisexplanationisthatitprovidesaplausibleexplanationfortheproductionofthe
onionringstructure.

Themarkertechniqueforfrictionstirweldingprovidesdataontheinitialandfinalpositionsofthemarkerinthe
weldedmaterial.Theflowofmaterialisthenreconstructedfromthesepositions.Detailedmaterialflowfield
duringfrictionstirweldingcanalsobecalculatedfromtheoreticalconsiderationsbasedonfundamentalscientific
principles.Materialflowcalculationsareroutinelyusedinnumerousengineeringapplications.Calculationof
materialflowfieldsinfrictionstirweldingcanbeundertakenbothusingcomprehensivenumerical
simulations[18][19][20]orsimplebutinsightfulanalyticalequations.[21]Thecomprehensivemodelsforthe
calculationofmaterialflowfieldsalsoprovideimportantinformationsuchasgeometryofthestirzoneandthe
torqueonthetool.[22][23]Thenumericalsimulationshaveshowntheabilitytocorrectlypredicttheresultsfrom
markerexperiments[20]andthestirzonegeometryobservedinfrictionstirweldingexperiments.[22][24]

Generationandflowofheat
Foranyweldingprocessitis,ingeneral,desirabletoincreasethetravelspeedandminimisetheheatinputasthis
willincreaseproductivityandpossiblyreducetheimpactofweldingonthemechanicalpropertiesoftheweld.At
thesametimeitisnecessarytoensurethatthetemperaturearoundthetoolissufficientlyhightopermitadequate
materialflowandpreventflawsortooldamage.

Whenthetraversespeedisincreased,foragivenheatinput,thereislesstimeforheattoconductaheadofthetool
andthethermalgradientsarelarger.Atsomepointthespeedwillbesohighthatthematerialaheadofthetoolwill
betoocold,andtheflowstresstoohigh,topermitadequatematerialmovement,resultinginflawsortoolfracture.
Ifthe"hotzone"istoolargethenthereisscopetoincreasethetraversespeedandhenceproductivity.

Theweldingcyclecanbesplitintoseveralstagesduringwhichtheheatflowandthermalprofilewillbe
different:[25]

Dwell.Thematerialispreheatedbyastationary,rotatingtooltoachieveasufficienttemperatureaheadof
thetooltoallowthetraverse.Thisperiodmayalsoincludetheplungeofthetoolintotheworkpiece.
Transientheating.Whenthetoolbeginstomovetherewillbeatransientperiodwheretheheatproduction
andtemperaturearoundthetoolwillalterinacomplexmanneruntilanessentiallysteadystateisreached.
Pseudosteadystate.Althoughfluctuationsinheatgenerationwilloccurthethermalfieldaroundthetool
remainseffectivelyconstant,atleastonthemacroscopicscale.
Poststeadystate.Neartheendoftheweldheatmay"reflect"fromtheendoftheplateleadingtoadditional
heatingaroundthetool.

Heatgenerationduringfrictionstirweldingarisesfromtwomainsources:frictionatthesurfaceofthetoolandthe
deformationofthematerialaroundthetool.[26]Theheatgenerationisoftenassumedtooccurpredominantlyunder
theshoulder,duetoitsgreatersurfacearea,andtobeequaltothepowerrequiredtoovercomethecontactforces
betweenthetoolandtheworkpiece.Thecontactconditionundertheshouldercanbedescribedbyslidingfriction,
usingafrictioncoefficientandinterfacialpressureP,orstickingfriction,basedontheinterfacialshearstrengthat
anappropriatetemperatureandstrainrate.Mathematicalapproximationsforthetotalheatgeneratedbythetool
shoulderQtotalhavebeendevelopedusingbothslidingandstickingfrictionmodels:[25]

https://en.wikipedia.org/wiki/Friction_stir_welding 6/12
09/12/2016 FrictionstirweldingWikipedia

(Sliding)

(Sticking)

whereistheangularvelocityofthetool,RshoulderistheradiusofthetoolshoulderandRpinthatofthepin.
Severalotherequationshavebeenproposedtoaccountforfactorssuchasthepinbutthegeneralapproachremains
thesame.

Amajordifficultyinapplyingtheseequationsisdeterminingsuitablevaluesforthefrictioncoefficientorthe
interfacialshearstress.Theconditionsunderthetoolarebothextremeandverydifficulttomeasure.Todate,these
parametershavebeenusedas"fittingparameters"wherethemodelworksbackfrommeasuredthermaldatato
obtainareasonablesimulatedthermalfield.Whilethisapproachisusefulforcreatingprocessmodelstopredict,
forexample,residualstressesitislessusefulforprovidinginsightsintotheprocessitself.

Applications
TheFSWprocessiscurrentlypatentedbyTWIinmostindustrialisedcountriesandlicensedforover183users.
Frictionstirweldinganditsvariantsfrictionstirspotweldingandfrictionstirprocessingareusedforthefollowing
industrialapplications:[27]shipbuildingandoffshore,[28]aerospace,[29][30]automotive,[31]rollingstockfor
railways,[32]generalfabrication,[33]robotics,andcomputers.

Shipbuildingandoffshore

TwoScandinavianaluminiumextrusioncompanieswerethefirsttoapply
FSWcommerciallytothemanufactureoffishfreezerpanelsatSapain
1996,aswellasdeckpanelsandhelicopterlandingplatformsatMarine
AluminiumAanensen.MarineAluminiumAanensensubsequentlymerged
withHydroAluminiumMaritimetobecomeHydroMarineAluminium.
SomeofthesefreezerpanelsarenowproducedbyRiftecandBayards.In
1997twodimensionalfrictionstirweldsinthehydrodynamicallyflared
bowsectionofthehulloftheoceanviewervesselTheBosswereproduced
atResearchFoundationInstitutewiththefirstportableFSWmachine.The
SuperLinerOgasawaraatMitsuiEngineeringandShipbuildingisthe
Frictionstirweldingwasusedto
largestfrictionstirweldedshipsofar.TheSeaFighterofNicholsBrosand
prefabricatethealuminiumpanelsof
theFreedomclassLittoralCombatShipscontainprefabricatedpanelsby
theSuperLinerOgasawaraatMitsui
theFSWfabricatorsAdvancedTechnologyandFrictionStirLink,Inc.
EngineeringandShipbuilding
respectively.[34]TheHoubeiclassmissileboathasfrictionstirwelded
rocketlaunchcontainersofChinaFrictionStirCentre.HMNZSRotoitiin
NewZealandhasFSWpanelsmadebyDonovansinaconvertedmillingmachine.[35][36]Variouscompaniesapply
FSWtoarmorplatingforamphibiousassaultships[37][38]

Aerospace

UnitedLaunchAllianceappliesFSWtotheDeltaII,DeltaIV,andAtlasVexpendablelaunchvehicles,andthe
firstofthesewithafrictionstirweldedInterstagemodulewaslaunchedin1999.Theprocessisalsousedforthe
SpaceShuttleexternaltank,forAresIandfortheOrionCrewVehicletestarticleatNASAaswellasFalcon1and
Falcon9rocketsatSpaceX.ThetoenailsforrampofBoeingC17GlobemasterIIIcargoaircraftbyAdvanced

https://en.wikipedia.org/wiki/Friction_stir_welding 7/12
09/12/2016 FrictionstirweldingWikipedia

JoiningTechnologies[39]andthecargobarrierbeamsfortheBoeing747
LargeCargoFreighter[39]werethefirstcommerciallyproducedaircraft
parts.FAAapprovedwingsandfuselagepanelsoftheEclipse500aircraft
weremadeatEclipseAviation,andthiscompanydelivered259frictionstir
weldedbusinessjets,beforetheywereforcedintoChapter7liquidation.
FloorpanelsforAirbusA400MmilitaryaircraftarenowmadebyPfalz
FlugzeugwerkeandEmbraerusedFSWfortheLegacy450and500Jets
[40]FrictionstirweldingalsoisemployedforfuselagepanelsontheAirbus

A380.[41]BRTJEAutomationGmbHusesfrictionstirweldingthrough Longitudinalandcircumferential
theDeltaNFSsystemforgantryproductionmachinesdevelopedforthe frictionstirweldsareusedforthe
aerospacesectoraswellasotherindustrialapplications.[42] Falcon9rocketboostertankatthe
SpaceXfactory
Automotive

AluminiumenginecradlesandsuspensionstrutsforstretchedLincoln
TownCarwerethefirstautomotivepartsthatwerefrictionstiratTower
Automotive,whousetheprocessalsofortheenginetunneloftheFordGT.
AspinoffofthiscompanyiscalledFrictionStirLink,Inc.and
successfullyexploitstheFSWprocess,e.g.fortheflatbedtrailer
"Revolution"ofFontaineTrailers.[43]InJapanFSWisappliedto
suspensionstrutsatShowaDenkoandforjoiningofaluminiumsheetsto
galvanizedsteelbracketsfortheboot(trunk)lidoftheMazdaMX5.
Frictionstirspotweldingissuccessfullyusedforthebonnet(hood)and ThecentretunneloftheFordGTis
reardoorsoftheMazdaRX8andthebootlidoftheToyotaPrius.Wheels madefromtwoaluminiumextrusions
arefrictionstirweldedatSimmonsWheels,UTAlloyWorksand frictionstirweldedtoabent
Fundo.[44]RearseatsfortheVolvoV70arefrictionstirweldedatSapa, aluminiumsheetandhousesthefuel
HVACpistonsatHallaClimateControlandexhaustgasrecirculation tank
[45]
coolersatPierburg.Tailorweldedblanks arefrictionstirweldedforthe
AudiR8atRiftec.[46]TheBcolumnoftheAudiR8Spiderisfrictionstirweldedfromtwoextrusionsat
HammererAluminiumIndustriesinAustria.

Railways

Since1997roofpanelsweremadefromaluminiumextrusionsatHydro
MarineAluminiumwithabespoke25mlongFSWmachine,e.g.forDSB
classSASDtrainsofAlstomLHB[47]Curvedsideandroofpanelsforthe
VictorialinetrainsofLondonUnderground,sidepanelsforBombardier's
Electrostartrains[48]atSapaGroupandsidepanelsforAlstom'sBritish
RailClass390PendolinotrainsaremadeatSapaGroup[49]Japanese
commuterandexpressAtrains,[50]andBritishRailClass395trainsare
frictionstirweldedbyHitachi,[51]whileKawasakiappliesfrictionstirspot
weldingtoroofpanelsandSumitomoLightMetalproducesShinkansen
Thehighstrengthlowdistortion
floorpanels.InnovativeFSWfloorpanelsaremadebyHammerer
bodyofHitachi'sAtrainBritishRail
AluminiumIndustriesinAustriafortheStadlerKISSdoubledeckerrail
Class395isfrictionstirweldedfrom
cars,toobtainaninternalheightof2monbothfloorsandforthenewcar
longitudinalaluminiumextrusions
bodiesoftheWuppertalSuspensionRailway.[52]

https://en.wikipedia.org/wiki/Friction_stir_welding 8/12
09/12/2016 FrictionstirweldingWikipedia

HeatsinksforcoolinghighpowerelectronicsoflocomotivesaremadeatSykatek,EBG,AusterlitzElectronics,
EuroComposite,Sapa[53]andRapidTechnic,andarethemostcommonapplicationofFSWduetotheexcellent
heattransfer.

Fabrication

FaadepanelsandcathodesheetsarefrictionstirweldedatAMAGand
HammererAluminiumIndustriesincludingfrictionstirlapweldsofcopper
toaluminium.Bizerbameatslicers,kolfterHVACunitsandSiemensX
rayvacuumvesselsarefrictionstirweldedatRiftec.Vacuumvalvesand
vesselsaremadebyFSWatJapaneseandSwisscompanies.FSWisalso
usedfortheencapsulationofnuclearwasteatSKBin50mmthickcopper
canisters.[54][55]Pressurevesselsfrom1msemisphericalforgingsof
38.1mmthickaluminiumalloy2219atAdvancedJoiningTechnologiesand
LawrenceLivermoreNatLab.[56]Frictionstirprocessingisappliedtoship
propellersatFrictionStirLink,Inc.andtohuntingknivesby
DiamondBlade.BoschusesitinWorcesterfortheproductionofheat
exchangers.[57]

Robotics

KUKARobotGrouphasadapteditsKR5003MTheavydutyrobotfor
frictionstirweldingviatheDeltaNFStool.Thesystemmadeitsfirst
publicappearanceattheEuroBLECHshowinNovember2012.[58] Thelidsof50mmthickcopper
canistersfornuclearwasteare
Personalcomputers attachedtothecylinderbyfriction
stirweldingatSKB
Appleappliedfrictionstirweldingonthe2012iMactoeffectivelyjointhe
bottomtothebackofthedevice.[59]

Seealso
Frictionwelding
Frictionstirprocessing
Category:Frictionstirweldingexperts
Frictionstirprocessedknivesby
References MegaStir

1.Thomas,WMNicholas,EDNeedham,JCMurch,MGTempleSmith,PDawes,CJ.Frictionstirbuttwelding,GB
PatentNo.9125978.8,InternationalpatentapplicationNo.PCT/GB92/02203,(1991)
2.Kallee,S.W.(20060906)."FrictionStirWeldingatTWI".TheWeldingInstitute(TWI).Retrieved20090414.
3.Ding,JeffBobCarterKirbyLawlessDr.ArthurNunesCarolynRussellMichaelSuitesDr.JudySchneider(2008
0214)."ADecadeofFrictionStirWeldingR&DAtNASA'sMarshallSpaceFlightCenterAndaGlanceintothe
Future"(PDF).NASA.Retrieved20090414.
4.Murr,LELiu,GMcClure,JC(1997)."Dynamicrecrystallisationinthefrictionstirweldingofaluminiumalloy1100".
JournalofMaterialsScienceLetters.16(22):18011803.doi:10.1023/A:1018556332357.
5.Krishnan,K.N.(2002)."OntheFormationofOnionRingsinFrictionStirWelds".MaterialsScienceandEngineering
A.327(2):246251.doi:10.1016/S09215093(01)014745.

https://en.wikipedia.org/wiki/Friction_stir_welding 9/12
09/12/2016 FrictionstirweldingWikipedia

6.Mahoney,M.W.Rhodes,C.G.Flintoff,J.G.Bingel,W.H.Spurling,R.A.(1998)."PropertiesofFrictionstir
welded7075T651Aluminum".MetallurgicalandMaterialsTransactionsA.29(7):19551964.doi:10.1007/s11661
99800215.
7.Nicholas,ED(1998)."Developmentsinthefrictionstirweldingofmetals".ICAA6:6thInternationalConferenceon
AluminiumAlloys.Toyohashi,Japan.
8.ByRajivS.Mishra,MurrayW.Mahoney:Frictionstirweldingandprocessing(https://books.google.com/books?id=JW2
l2LUYS4C&lpg=PA31&ots=_jlL5ZA32r&dq=friction%20stir%20processing%20propeller&hl=en&pg=PA7#v=onepage
&q=friction%20stir%20processing%20propeller&f=false),ASMInternationalISBN9780871708489.
9.Prado,RAMurr,LEShindo,DJSoto,HF(2001)."Toolwearinthefrictionstirweldingofaluminiumalloy
6061+20%Al2O3:Apreliminarystudy".ScriptaMaterialia.45:7580.doi:10.1016/S13596462(01)009940.
10.Nelson,TZhang,HHaynes,T(2000)."frictionstirweldingofAlMMC6061B4C".2ndInternationalSymposiumon
FSW(CDROM).Gothenburg,Sweden.
11.BhadeshiaHKDHDebRoyT(2009)."Criticalassessment:frictionstirweldingofsteels".ScienceandTechnologyof
WeldingandJoining.14(3):193196.doi:10.1179/136217109X421300.
12.RaiRDeABhadeshiaHKDHDebRoyT(2011)."Review:frictionstirweldingtools".ScienceandTechnologyof
WeldingandJoining.16(4):325342.doi:10.1179/1362171811Y.0000000023.
13."Aflowpartitioneddeformationzonemodelfordefectformationduringfrictionstirwelding".ScriptaMaterialia.58:
372376.doi:10.1016/j.scriptamat.2007.10.031.
14.Leonard,AJ(2000)."MicrostructureandagingbehaviourofFSWinAlalloys2014AT651and7075T651".2nd
InternationalSymposiumonFSW(CDROM).Gothenburg,Sweden.
15.Reynolds,AP(2000)."Visualisationofmaterialflowinautogenousfrictionstirwelds".Scienceandtechnologyof
weldingandjoining.5(2):120124.doi:10.1179/136217100101538119.
16.Seidel,TUReynolds,AP(2001)."VisualizationoftheMaterialFlowinAA2195FrictionStirWeldsUsingaMarker
InsertTechnique".MetallurgicalandMaterialTransactions.32A(11):28792884.
17.Guerra,MSchmidt,CMcClure,JCMurr,LENunes,AC(2003)."Flowpatternsduringfrictionstirwelding".
MaterialsCharacterisation.49(2):95101.doi:10.1016/S10445803(02)003625.
18.NandanRDebRoyTBhadeshiaHKDH(2008)."RecentadvancesinfrictionstirweldingProcess,weldmentstructure
andproperties".ProgressinMaterialsScience.53(6):9801023.doi:10.1016/j.pmatsci.2008.05.001.
19.NandanR,RoyGG,LienertTJ,DebRoyT(2007)."Threedimensionalheatandmaterialflowduringfrictionstir
weldingofmildsteel".ActaMaterialia.55(3):883895.doi:10.1016/j.actamat.2006.09.009.
20.SeidelTU,ReynoldsAP(2003)."Twodimensionalfrictionstirweldingprocessmodelbasedonfluidmechanics".
ScienceandTechnologyofWeldingandJoining.8(3):175183.doi:10.1179/136217103225010952.
21.AroraADebRoyTBhadeshiaHKDH(2011)."BackoftheenvelopecalculationsinfrictionstirweldingVelocities,
peaktemperature,torque,andhardness".ActaMaterialia.59(5):20202028.doi:10.1016/j.actamat.2010.12.001.
22.AroraA,NandanR,ReynoldsAP,DebRoyT(2009)."Torque,powerrequirementandstirzonegeometryinfrictionstir
weldingthroughmodelingandexperiments".ScriptaMaterialia.60(1):1316.doi:10.1016/j.scriptamat.2008.08.015.
23.MehtaM,AroraA,DeA,DebRoyT(2011)."ToolGeometryforFrictionStirWeldingOptimumShoulderDiameter".
MetallurgicalandMaterialsTransactionsA.42(9):27162722.doi:10.1007/s1166101106725.
24.NandanR,RoyGG,DebRoyT(2011)."Numericalsimulationofthreedimensionalheattransferandplasticflowduring
frictionstirwelding".MetallurgicalandMaterialsTransactionsA.37(4):12471259.doi:10.1007/s1166100610769.
25.Frigaard,OGrong,OMidling,OT(2001)."Aprocessmodelforfrictionstirweldingofagehardeningaluminium
alloys".MetallurgicalandMaterialTransactions.32A(5):11891200.doi:10.1007/s1166100101284.
26.Qi,X,Chao,YJ(1999)."HeattransferandThermoMechanicalanalysisofFSWjoiningof6061T6plates".1st
InternationalSymposiumonFSW(CDROM).ThousandOaks,USA:TWI.
27.D.LohwasserandZ.Chen:"FrictionstirweldingFrombasicstoapplications"WoodheadPublishing2010(http://ww
w.woodheadpublishing.com/en/book.aspx?bookID=1503),Chapter5,Pages118163,ISBN9781845694500.
28.FredDelany,StephanWKallee,MikeJRussell:"Frictionstirweldingofaluminiumships"(http://www.twi.co.uk/conten
t/spswkjune07.html),Paperpresentedat2007InternationalForumonWeldingTechnologiesintheShippingIndustry
(IFWT).HeldinconjunctionwiththeBeijingEssenWeldingandCuttingFairinShanghai,1619June2007.
29.Video:''FSWatBritishAerospace''(http://www.twi.co.uk/jsp/flashlist.jsp?flash=Friction%20stir%20welding%20at%20
British%20Aerospace.flv).Twi.co.uk.Retrievedon20120103.
30.Video:FSWofaerospacefuselages(http://www.twi.co.uk/jsp/flashlist.jsp?flash=Friction%20stir%20welding%20of%20a
ircraft%20fuselages.flv).Twi.co.uk.Retrievedon20120103.
31.S.W.Kallee,J.M.Kell,W.M.ThomasundC.S.Wiesner:"Developmentandimplementationofinnovativejoining
processesintheautomotiveindustry"(http://www.twi.co.uk/content/spswksept2005.html),PaperpresentedatDVS
AnnualWeldingConference"GroeSchweitechnischeTagung",Essen,Germany,1214September2005.

https://en.wikipedia.org/wiki/Friction_stir_welding 10/12
09/12/2016 FrictionstirweldingWikipedia

32.S.W.KalleeandJ.Davenport:"Trendsinthedesignandfabricationofrollingstock"(http://www.twi.co.uk/technicalkn
owledge/publishedpapers/trendsinthedesignandfabricationofrollingstockjanuary2007/),Paperpublishedin
EuropeanRailwayReview,Volume13,Issue1,2007.
33.MikePage:"Frictionstirweldingbroadensapplicationsbase"
(http://www.manufacturingtalk.com/news/mij/mij107.html),ReportofaEuroStirmeeting,3Sept2003.
34.BillArbegast,TonyReynolds,RajivS.Mishra,TracyNelson,DwightBurford:LittoralCombatSystemwithImproved
WeldingTechnologies(http://faculty.washington.edu/scottcs/NSF/2009/CFSP.pdf),CenterforFrictionSTIRProcessing
(CFSP).
35.RichardWorrall:"WeldedBliss"(http://www.camtec.org.nz/downloads/IPENZFSWArticle.pdf),e.nzmagazine
March/April2008.
36.StephanKallee:"NZFabricatorsbegintouseFrictionStirWeldingtoproducealuminiumcomponentsandpanels"(http://
www.twi.co.uk/content/spswkaug2006.html),PaperpublishedinNewZealandEngineeringNews,August2006.
37.FrictionStirWeldingDemonstratedforCombatVehicleConstruction...for2519aluminiumarmorfortheU.S.Marine
Corps'AdvancedAmphibiousAssaultVehicle(http://www.aws.org/w/a/wj/2003/03/feature3/index.html),Welding
Journal032003.
38.GCampbellandTStotler:FrictionStirWeldingofArmorGradeAluminumPlate(http://www.aws.org/wj/dec99/campbel
l.html),WeldingJournal,Dec1999.
39.WalterPolt"AlittlefrictionatBoeing"(http://www.boeing.com/news/frontiers/archive/2004/september/i_tt.html),
BoeingFrontiersOnline,September2004,Vol.3,Issue5
40.EmbraerPerformsFirstMetalCutforLegacy500Jet(http://www.bartintl.com/content/embraerperformsfirstmetalcut
legacy500jet),BARTInternational.
41."HowAirbususesfrictionstirwelding".ReliablePlant.Retrieved7August2013.
42."JECCompositesShowDay3:EADSlicensesitspatentedDeltaNfrictionstirweldingtechnologytoBRTJE
Automation".EADS.Retrieved30July2013.
43.ARevolutionmakesalotofdifference(http://www.fontainetrailer.com/pdfs/Revolution%20Aluminum.pdf).
fontainetrailer.com
44.Fundo'sFSWWheelsprovideimprovedperformanceandreducedrunningcosts(http://www.twi.co.uk/content/autonews.
html#wheel).twi.co.uk/
45.FSWusedinautomotivetailorweldedblanks(http://www.twi.co.uk/jsp/flashlist.jsp?flash=FSW%20used%20in%20aut
o%20blanks.flv).Twi.co.uk.Retrievedon20120103.
46.FSWapplicationsatRiftec(http://www.riftec.de/joiningprocesses/frictionstirwelding/applications/?L=2),riftec.de.
47.S.W.Kallee,J.DavenportandE.D.Nicholas:"RailwayManufacturersImplementFrictionStirWelding"(http://www.aw
s.org/wj/oct02/feature.html),WeldingJournal,October2002.
48.Video:''FrictionstirweldingofBombardiertrains''(http://web.archive.org/web/20110927181625/http://www.twi.co.uk/js
p/flashlist.jsp?flash=Trainmakers%20adopt%20friction%20stir.flv),archivedfromtheoriginal(http://www.twi.co.uk/jsp/
flashlist.jsp?flash=Trainmakers%20adopt%20friction%20stir.flv)on27September2011.Twi.co.uk.
49.Sapa'sCapabilities(http://www.sapagroup.com/en/Companysites/SapaMassTransportation/FSW/LonglengthFSW),
LonglengthFSWMax.length26mMax.width3,5mDoublesidedwelding,Sapacompanybrochure.
50.History,PrinciplesandAdvantagesofFSWonHitachiTransportationSystemsWebsite(http://www.hitachirail.com/pro
ducts/rv/a_train/features/index_2.html).Hitachirail.com.Retrievedon20120103.
51.HitachiClass395RailwayStrategiesLive2010(http://www.railalliance.co.uk/docs/rsl10hitachi.pdf).23June2010,pp.
1213.(PDF).Retrievedon20120103.
52.F.Ellermann,S.Pommer,G.Barth:EinsatzdesRhrreibschweiensbeiderFertigungderWagenkstenfrdie
SchwebebahnWuppertal.(https://www.dvsev.de/call4papers/images/70/20140915_ProgrammDVSCongress2014.pdf)
DVSCongress:GroeSchweitechnischeTagung,15./16.September,HotelPullmanBerlinSchweizerhof,Berlin.
53.FSW:Increasedstrength,Improvedleakproofness,Improvedrepeatability.Reducedheatdistortion(http://www.sapagrou
p.com/Companies/Sapa%20Thermal%20Management/files/FSW_folder_Eng.pdf),Sapacompanybrochure.
54.Video:''ElectronBeamWeldingandFrictionStirWeldingofCopperCanisters''(http://www.twi.co.uk/newsevents/video
s/canistersealingfornuclearwasteeborfsw/).Twi.co.uk.Retrievedon20120103.
55.Nielsen,Isak(2012).ModelingandControlofFrictionStirWeldingin5cm(2in)thickCopperCanisters(M.Sc.
thesis).LinkpingUniversity.
56.EDalder,JWPasternak,JEngel,RSForrest,EKokko,KMcTernanandDWaldronFrictionstirweldingofthick
walledalumniumpressurevessels(http://research.vuse.vanderbilt.edu/vuwal/Research/SphDocs/LwrncLvrmrFSWpressV
essels.pdf),WeldingJournal,April2008,pp.4044.
57.YouTubeVideo.(https://www.youtube.com/watch?v=eyV3rKNd3x8&)
58."PartnershipsuccesswithEADS'DeltaNFSfrictionstirweldingtechnologyforindustrialrobots".EADS.Retrieved
30July2013.
https://en.wikipedia.org/wiki/Friction_stir_welding 11/12
09/12/2016 FrictionstirweldingWikipedia

59."Appleunveilstotallyredesigned27and21.5imac".TechCrunch.

Externallinks
FrictionstirweldingatTWI(http://www.twi.co.uk/technologies/weldingcoatingandmaterialprocessing/fri
ctionstirwelding/)
FrictionstirweldingresearchatUniversityofCambridge(http://www.msm.cam.ac.uk/phasetrans/2003/FS
W/aaa.html)
Frictionstirweldingofaluminumalloytosteelacademicarticlefromthe2004WeldingJournal(http://file
s.aws.org/wj/supplement/102004KIMAPONGs.pdf)
FrictionstirweldingresearchatVanderbiltUniversityWeldingAutomationLaboratory(http://research.vuse.
vanderbilt.edu/vuwal/index.shtml)
Backoftheenvelopecalculationsinfrictionstirwelding(http://www2.matse.psu.edu/modeling/boe_manua
l.pdf)
Theoryofmaterialsprocessing/weldingresearchgroupatPennStateUniversity(http://www2.matse.psu.ed
u/modeling/)
FrictionStirWeldingMachines:Applications&KeyFeatures(http://www.holroyd.com/heavyindustries/ne
wmachines/frictionstirwelding.php)

Retrievedfrom"https://en.wikipedia.org/w/index.php?title=Friction_stir_welding&oldid=752074355"

Categories: Welding Friction

Thispagewaslastmodifiedon29November2016,at10:21.
TextisavailableundertheCreativeCommonsAttributionShareAlikeLicenseadditionaltermsmayapply.
Byusingthissite,youagreetotheTermsofUseandPrivacyPolicy.Wikipediaisaregisteredtrademark
oftheWikimediaFoundation,Inc.,anonprofitorganization.

https://en.wikipedia.org/wiki/Friction_stir_welding 12/12