Friction Stir Welding

Numerical model for prediction of tool wear and worn-out pin profile during friction stir welding

Understanding tool wear during friction stir welding (FSW) is important for joining of high melting point metallic (HMPM) materials. Heat transfer and material flow based models developed in past have improved understanding of the FSW process. …

Wear-induced changes in FSW tool pin profile: effect of process parameters

Friction stir welding (FSW) of high melting point metallic (HMPM) materials has limited application due to tool wear and relatively short tool life. Tool wear changes the profile of the tool pin and adversely affects weld properties. A quantitative …

Microstructure and mechanical properties of friction stir processed cast Eglin steel (ES-1)

Eglin steel, an ultra-high-strength steel developed for various demanding applications, is a low-cost alternative to 4340 steel, in which nickel and cobalt additions are replaced by higher tungsten additions, thereby achieving comparable strength and …

Quantitative wear analysis of H13 steel tool during friction stir welding of Cu-0.8% Cr-0.1% Zr alloy

Joining of high strength materials using friction stir welding (FSW) is difficult due to severe tool wear and change in the shape/size of the tool. However, quantitative understanding of tool wear during FSW of high melting point metallic materials …

An assisted heating tool design for FSW of thermoplastics

An assisted heating tool design was used to obtain better weld surface finish, and lower chip formation and material loss during friction stir welding (FSW) of thermoplastics. The welded coupons of polypropylene with various tool rotational speeds …

A framework for shear driven dissolution of thermally stable particles during friction stir welding and processing

A framework is proposed to explain the dissolution and fragmentation of particles during friction stir welding and processing. Two major mechanisms dissolve the particle during the process: (i) thermally activated diffusion, and (ii) dislocation and …

Load Bearing Capacity of Tool Pin during Friction Stir Welding

Although friction stir welding (FSW) is now widely used for the welding of aluminum and other soft alloys, premature tool failure limits its application to hard alloys such as steels and titanium alloys. The tool pin, the weakest component of the …

Tool durability maps for friction stir welding of an aluminium alloy

Friction stir welding is not used for hard alloys because of premature tool failure. A scheme is created that exploits th physical three-dimensional heat and mass flow models, and implements them into a fast calculation algorithm, which, when combine …

Neural network models of peak temperature, torque, traverse force, bending stress and maximum shear stress during friction stir welding

Tool and workpiece temperatures, torque, traverse force and stresses on the tools are affected by friction stir welding (FSW) variables such as plate thickness, welding speed, tool rotational speed, shoulder and pin diameters, pin length and tool …

Tool geometry for friction stir welding – optimum shoulder diameter

The most important geometric parameter in the friction stir welding (FSW) tool design is the shoulder diameter, which is currently estimated by trial and error. Here, we report a combined experimental and theoretical investigation on the influence of …