Working Principle of FSP A specially designed non- consumable cylindrical tool is rotated and plunged into the selected

d area, to friction process the required location within a plate or sheet Tool has a small diameter pin with a concentric larger diameter shoulder Tool shoulder and length of entry probe control the penetration depth When tool descended to the part, the rotating pin contacts the surface, rapidly friction produced between tool pin and metal surface heats and softens a small column of metal Rotating tool provides: Continuous heating of work piece Plasticizing metal Transporting metal from the leading face of the pin to its trailing edge

When the shoulder contacts the metal surface, its rotation creates additional frictional heat and plasticizes a larger cylindrical metal column around the inserted pin The shoulder additionally provides a forging force that contains the upward metal flow caused by the tool pin During FSP, work piece and the tool are moved relative to each other such that the tool traverses, with overlapping passes, until the required area is processed The processed zone cools, without solidification, as there is no liquid, forming a defect-free recrystallized, fine grain microstructure

Applications of FSP FSP has been shown as an effective technique in following applications To fabricate surface composites To refine microstructure of cast light alloys To produce fine-grain microstructure, which exhibits superplasticity

Friction Stir Processing is the effective technique (by locally alters the microstructure )

To produce surface composites To improve mechanical properties of cast light alloys To incorporate superplasticity

Future studies in this field includes material flow, tool geometry design, tool wear and microstructural stability 2. Process parameters FSW/FSP involves complex material movement and plastic deformation. Welding parameters, tool geometry, and joint design exert significant effect on the material flow pattern and temperature distribution, thereby influencing the microstructural evolution of material. In this section, a few major factors affecting FSW/FSP process, such as tool geometry, welding parameters, joint design are addressed. 2.1. Tool geometry Tool geometry is the most influential aspect of process development. The tool geometry plays a critical role in material flow and in turn governs the traverse rate at which FSW can be conducted. An FSW tool consists of a shoulder and a pin as shown schematically in Fig. 2. As mentioned earlier, the tool has two primary functions: (a) localized heating, and (b) material flow. In the initial stage of tool plunge, the heating results primarily from the friction between pin and workpiece. Some additional heating results from deformation of material. The tool is plunged till the shoulder touches the workpiece. The friction between the shoulder and workpiece results in the biggest component of heating. From the heating aspect, the relative size of pin and shoulder is important, and the other design features are not critical. The shoulder also provides confinement for the heated volume of material. The second function of the tool is to stir and move the material. The uniformity of microstructure and properties as well as process loads are governed by the tool design. Generally a concave shoulder and threaded cylindrical pins are used. With increasing experience and some improvement in understanding of material flow, the tool geometry has evolved significantly. Complex features have been added to alter material flow, mixing and reduce process loads. For example, WhorlTM and MX TrifluteTM tools developed by TWI are
R.S. Mishra, Z.Y. Ma / Materials Science and Engineering R 50 (2005) 178 3 Fig. 2.

Advantages and limitations

The solid-state nature of FSW immediately leads to several advantages over fusion welding methods since any problems associated with cooling from the liquid phase are immediately

avoided. Issues such as porosity, solute redistribution, solidification cracking and liquation cracking are not an issue during FSW. In general, FSW has been found to produce a low concentration of defects and is very tolerant to variations in parameters and materials. Nevertheless, FSW is associated with a number of unique defects. Insufficient weld temperatures, due to low rotational speeds or high traverse speeds, for example, mean that the weld material is unable to accommodate the extensive deformation during welding. This may result in long, tunnel-like defects running along the weld which may occur on the surface or subsurface. Low temperatures may also limit the forging action of the tool and so reduce the continuity of the bond between the material from each side of the weld. The light contact between the material has given rise to the name "kissing-bond". This defect is particularly worrying since it is very difficult to detect using nondestructive methods such as X-ray or ultrasonic testing. If the pin is not long enough or the tool rises out of the plate then the interface at the bottom of the weld may not be disrupted and forged by the tool, resulting in a lack-ofpenetration defect. This is essentially a notch in the material which can be a potent source of fatigue cracks. A number of potential advantages of FSW over conventional fusion-welding processes have been identified:[5]

Good mechanical properties in the as welded condition Improved safety due to the absence of toxic fumes or the spatter of molten material. No consumables A threaded pin made of conventional tool steel, e.g., hardened H13, can weld over 1 km of aluminium, and no filler or gas shield is required for aluminium. Easily automated on simple milling machines lower setup costs and less training. Can operate in all positions (horizontal, vertical, etc.), as there is no weld pool. Generally good weld appearance and minimal thickness under/over-matching, thus reducing the need for expensive machining after welding. Low environmental impact.

However, some disadvantages of the process have been identified:

Exit hole left when tool is withdrawn. Large down forces required with heavy-duty clamping necessary to hold the plates together. Less flexible than manual and arc processes (difficulties with thickness variations and non-linear welds). Often slower traverse rate than some fusion welding techniques, although this may be offset if fewer welding passes are required. Friction stir welding process Friction stir welding is a new solid state joining process. Here a cylindrical shouldered tool along with a profiled probe is rotated and fed at a constant traverse rate in to the joint. Frictional heat generated between the wear resistant welding tool and the workpiece along with mechanical mixing heat causes the stirred material to soften without reaching the melting point and allows the traversing of the tool along the weld line.

 The plasticised material is transferred from the leading edge of the tool to its trailing edge and is forged by the intimate contact of the tool shoulder and the pin profile thus leaving a solid bond between two phases Materials and thickness Friction stir welding can be used for joining 2000, 5000,6000,7000 series aluminium. Aluminium based metal matrix composites Copper and its alloys (up to 50mm in one pass). Lead. Titanium and its alloys. Zinc, plastic, stainless steel and nickel alloys. Process advantages Low distortion, even in long welds. Excellent mechanical properties as proven by fatigue, tensile and bend tests. No arc, fume, spatter and porosity low shrinkage. Can operate in all positions. Non consumable tool. No filler wire, gas shielding. Can weld aluminium and copper of >50mm thickness on one pass Applications of friction stir welding 1. Ship building and marine industries Panels for decks, bulk heads and floors Hulls and superstructures Helicopter landing platforms Mast and booms (sailing boat) 2. Aerospace industry cryogenic fuel tank for space vehicles Aviation fuel tanks Military and scientific rockets Various primary and secondary structural component 3. Railway and Land transport. high speed trains railway tankers and goods wagon wheel rims motor cycle and bicycle frames Limitations of Friction stir welding Workpieces must be rigidly clamped Backing bar required (except for self reacting and directly opposed tools) Key holes at the end of each weld Cannot make joints that require metal deposition Less flexible than manual and arc processes Conclusion New technology with vital application in aerospace an marine

Presently limited to aluminium ,its alloys and related metals FSW of steel and titanium alloys are developed and they are in the nascent stage Will emerge as a better welding technology

Reference: http://seminarprojects.com/Thread-friction-stir-weldingpresentation#ixzz1q0qDmcUl