FRICTION WELDING

VS
FRICTION STIR WELDING

By k.prasana
181002118
 FRICTION WELDING

 It is a solid state process in which

coalescences is achieved by heat along with
pressure.
 Works on a simple principal of friction.

 No melting occur at the faying surfaces.

 Unlike fusion welding ,no filler metal is used.

 Has less heat affected zone(HAZ).

 This process is used to weld dissimilar metals.

FRICTION WELDING
 APPLICATION AND LIMITATIONS OF FW
 Applications:
1.For welding tubes and shafts.
2.It is mostly used in aerospace, automobile, marine and oil industries.
3. Used in electrical industries for welding copper and aluminum
equipments.
 Limitations:
1. This is mostly used only for round bars of same cross section.
2.Non-forgeable material cannot be weld.
3.Preparation of work piece is more critical
4.High setup cost.
5.Joint design is limited.
 FRICTION STIR WELDING
 A solid-state joining process that uses a non-consumable tool
to join two facing workpieces without melting the workpiece
material.
 Unlike friction welding ,the heat is generated by a rotating
cylindrical tool with a profiled probe .
 FSW is capable of joining aluminium alloys, cooper alloys,
titanium alloys, mild steel, stainless steel and magnesium
alloys.
 FSW doesn’t have problems such as porosity, solidification
cracking etc.
 A non-consumable probe is used and no toxic fumes are
released.
FRICTION STIR WELDING PROCESS
 APPLICATIONS AND LIMITATIONS OF FSW
 Applications:
1.Shipbuilding and offshore
2.Aerospace
3.Automotive
 Limitations:
1.an exit hole is produced when the rotating tool is removed.
2. Tool rotation and traverse speeds
3. Tool tilt and plunge depth(an ideal tilt of 2-4 degrees)
4.heavy clamping is required for better weld .
 FRICTION WELDING
 Used to weld dissimilar metals.
 Less heat is produced in this
process.
 Its produces less HAZ
compared to FSW.
 Reduce in the dimension of the
material after the process.
 No external rotating machine is
required.
FRICTION STIR WELDING
 But it is used primilary for
aluminium alloys.
 Heat is generated between the
rotating tool and the workpiece.
 It produces HAZ,TMAZ due to
the heat associated to it.
 Reduction in the thickness of
the material.
 An rotating machine is required
for welding .