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INTRODUCTION
Welding using friction as the major resource No filler material involved Welds created by,
FRICTION WELDING
Heat from mechanical energy conversion Linear friction welding Rotary friction welding
MICROSTRUCTURE ANALYSIS
A. Unaffected material B. Heat affected zone (HAZ) C. Thermo-mechanically affected zone (TMAZ) D. Weld nugget (Part of thermo-mechanically affected zone)
Root surface
JOINT GEOMETRIES
MATERIAL SUITABILITY
Copper and its alloys Lead Titanium and its alloys Magnesium alloys Zinc Plastics Mild steel Stainless steel Nickel alloys
TOOLS PARAMETERS
COMMON TOOLS
ESAB Machine
ADVANTAGES
Diverse materials: Welds a wide range of alloys, including previously un-weldable (and possibly composite materials) Durable joints: Provides twice the fatigue resistance of fusion welds. Versatile welds: Welds in all positions and creates straight or complexshape welds Retained material properties: Minimizes material distortion Safe operation: Does not create hazards such as welding fumes, radiation, high voltage, liquid metals, or arcing
DISADVANTAGES
Work pieces must be rigidly clamped Backing bar required (except where self-reacting tool or directly opposed tools are used) Keyhole at the end of each weld Cannot make joints which required metal deposition (e.g. fillet welds)
FUTURE DEVELOPMENTS
Laser-assisted friction stir welding Possible use of induction coil and other mechanism
APPLICATIONS
Ship building Space applications
AIM
FSW of dissimilar materials
Feasibility
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