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Introduction
Welding using friction as the major resource No filler material involved Welds created by,
a) Frictional heating b) Mechanical deformation
History
Invented by TWI in 1991 in England 28 organizations worldwide use FSW
Friction Welding
Heat from mechanical energy conversion
Linear friction welding Rotary friction welding
Rotating probe provides friction heat and pressure which joins the material Sufficient downward force to maintain pressure and to create friction heat
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)
Microstructure analysis
Optical micrographs of regions (a), (b) and (c) of the stir nugget.
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 complex-shape 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
Conclusion
An alternative to fusion welding Advanced technologies are in the offing
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