Friction Stir Welding

Friction stir welding

FSW of Aluminum with PP : Joining different parts that too made of different materials is one of the essential steps while designing/engineering of materials. Presently, the energy-efficient low-weight automotive and aerospace components consist of many classes of materials, such as metals, polymers, ceramics, etc. Efficient and reliable joining of such materials of varied nature is a daunting task. We have demonstrated, for the first time, joining of a metal (aluminum) and a polymer (Polypropylene, pp) using mechanical friction.

Modeling and Simulation of advanced manufacturing processes

Modeling and Simulation of advanced manufacturing processes

Friction stir welding of additively manufactured Ti-6Al-4V: Microstructure and mechanical properties

Additive manufacturing of titanium alloy Ti-6Al-4V has significantly increased over the past few years, primarily due to its broad application over the conventional manufacturing process for complex and near net shape production. However, …

Heat transfer modeling of dissimilar FSW of Al 6061/AZ31 using experimentally measured thermo-physical properties

A heat transfer numerical model is developed for friction stir welding of dissimilar materials Al 6061 and AZ31 alloy. Thermo-physical properties were experimentally determined for the stir zone and compared with the base alloys. Experimentally …

Friction Stir Welding of Copper: Numerical Modeling and Validation

High thermal and electrical conductivities, corrosion resistance and relatively good strength lead to use of copper and its alloys for several engineering applications. Copper alloys also find application in the nuclear industry for manufacturing …

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. …

Towards attaining dissimilar lap joint of CuCrZr alloy and 316L stainless steel using friction stir welding

CuCrZr alloy (Cu-0.8wt-%Cr-0.1wt-%Zr) and 316L stainless steel (Fe-0.03wt-%C-16wt-%Cr-10wt-%Ni) plates were successfully friction stir lap welded resulting in significant mechanical mixing of the two matrix elements, Cu and Fe, in the stir zone. The …

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 …