REGISTRATION SEMINAR

BY
KANCHAN KUMARI(10ME90R20)
UNDER THE GUIDANCE OF
DR. SURJYA K. PAL
Department of Mechanical Engineering
Indian Institute of Technology, Kharagpur

INTRODUCTION

FRICTION STIR PROCESSING

LITERATURE REVIEW

OBJECTIVES

EXPERIMENTAL SETUP

RESULT AND DISCUSSION

FUTURE WORK

CONCLUSION

Friction stir welding (FSW) is a solid state joining

process.

Invented at The Welding Institute (TWI) of

Cambridge, UK in 1991.

Utilizes a non consumable rotating tool consisting of

a concentric threaded tool pin and tool shoulder.

Transforms the metal from a solid state into a

Plastic like state and the mechanically stir the
materials together under pressure to form a welded
joint.
Schematic representation of FSW
Contd.
SEQUENCE OF OPERATION
Contd.
Contact of the pin produces friction and deformational
heating.
Contact of shoulder to the work piece increases the
work piece heating and expands the zone of softened
material and constrained the deformed material.
A. Unaffected material
B. Heat affected zone (HAZ)
C. Thermo-mechanically affected zone (TMAZ)
D. Weld nugget (Part of thermo-mechanically
affected zone)

Aerospace

Ship building

Railway industries

Automobiles

Some of the parts are-

Fuel tank for space launch vehicles.

Roofing for railway carriages.

Bodies and floors for coaches, buses.

Wings and fuselage panels of aircraft.

Wheel assemblies.

Connectors.

Retain near-parent material properties across the

weld.

Join similar and dissimilar material, difficult by

conventional processes.

Weld quality is excellent (no porosity).

No melting of material.

Low residual stresses.

No fumes, no filler material, no shielding gases.

Easily automated on simple milling machine-low

setup cost and less training.
Machine variable Tool variable Other variable
Welding speed
Spindle speed
Plunge force
Tool tilt angle
Tool material
Pin and shoulder diameter
Pin length
Thread pitch
Shoulder and tool feat
Joint design
Material Type and size
Property of work piece
material
Type of fixture material
PROCESS VARIABLES IN FSW

Tool rotation rate and traverse speed are the most

important welding parameters in FSW.

The tool rotation results in stirring and mixing of the

material around the tool pin and the traverse speed
results in movement of material from the front to back
and complete welding process.

High rotation results in high temperature due to high

frictional heating. With increase in temperature frictional
coupling occur between the tool surface and work piece.
Therefore monotonic increases in heating with increasing
tool rotation rate is not expected as the coefficient of
friction at interface will change with increasing tool
rotation rate.
Author Year Findings
Sato et al. 2002 Significant rise of temperature with rise of rotational
speed.
Peel et al. 2006 Both torque and extent of material mixing in the SZ
zone displays a much stronger dependence on the
rotational speed than the traverse speed.
Meran et al. 2006 With const.rpm and varying welding speed finding
out the optimum parameter for defect-free joint
Kwo et al. 2009 Onion ring structure becomes wider as rpm
increased. but grain size decreased with decrease in
rpm.
Rodrigues et al. 2009 Hot weld obtained with maximum rpm and minimum
traverse speed have improved mechanical
properties relative to cold weld.
Raja manickram
et al.
2008 Temperature under the tool was strongly dependent
on the tool rotation rate than the welding speed.
Azizieh et al. 2011 With high rpm, higher heat input occur and
simultaneously more shattering effect of rotation
cause better nano-particle distribution.

Tool geometry is the most influential aspect of

process development which plays a critical role in
the material flow and in turn governs the traverse
rate at which it can be conducted.

FSW tool consist of a pin and a shoulder..

Selection of tool material is also very important.

Tool steel, cobalt-nickel base alloy, tungsten-base
alloy, nickel alloy, PCBN alloy are the different tool
materials used for FSW.
Contd.
Schematic drawing of FSW tool
Contd.
A selection of tools designed at TWI
Contd.
Tool shoulder geometries, viewed from
underneath the shoulder
Author Year Findings
Scialpi et al. 2007 Used 3 different shoulder geometry (scroll with fillet, cavity
with filet, only fillet)and found that best joint has been
welded by shoulder with fillet.
Zhang et al. 2011 Tool with three spiral flute w/o pin gives better result than
inner concave flute and concentric circle flute.
Forcellese et al. 2012 Used two different tool configuration with different values
of shoulder diameter, both with and w/o pin.
Large shoulder diameter w/o pin gives strong beneficial
effect on both ductility and strength.
Forcellese et al. 2012 Investigated the plastic flow behavior and formability of
FSW AZ31 thin sheet using pin-less tool configuration.
Galvao et al. 2012 Used scrolled and conical shoulder tool. Found that
different geometry had completely different morphology
and intermetallic content using same process parameter.
Galvao et al. 2013 Further researched to see the influence of 3 different
geometry (flat, conical, scrolled) on 1 mm thick copper
plate..

In FSW, heat generated by friction between the tool

and work piece.

The temperature within and around the stirred zone

influence the microstructure of the weld and resultant
mechanical properties.

Temperature data acquisition done by 4 K-type

thermocouples.

It shows that the temperature is uniform and starts

from the rim of the pin to the edge of the work piece.

FSW process can be defined as a metal working

process of five conventional metal working zones.

Preheat

Initial deformation

Extrusion

Forging

Post heat / cool down

Contd.
(a) Metal flow pattern and (b) Metallurgical processing
zones developed during friction stir welding

The microstructure and consequent property

distribution produced during FSW depends on
following factors :

Alloy composition

Alloy temper

Welding parameters

Other geometric factors (Shoulder size, Plate gauge,

etc)
Author Year Findings
Guerra et al. 2003 Studied the flow of metal using faying surface tracer
and a nib frozen in place during welding. Material is
moved around the nib by two processes both having
different thermo mechanical histories and properties.
Hamilton et al. 2008 Proposed a model of material flow during FSW. They
observed that NZ is the combination of interleaved
layers of particle rich and particle poor material.
Sato et al. 2002 Grain size in the nugget region is determined
predominantly by the peak temperature in the weld.
Higher the peak temperature larger is the grain size.
Formation of defects are mainly due to improper material flow
or due to geometric factors.

Lack of penetration

Lack of fusion

Surface grooves

Excessive flash

Surface galling

Tunnels

Voids

Nugget collapse

Kissing bonds

Too cold welding condition results in work hardening

of the material.

Causes dry slip between the tool and work piece.

Lack of surface fills/ voids, channel defects are the

main defects due to insufficient heat generation.

The insufficient heat generation causes improper

material mixing and thus responsible for non-
bonding.
Author Year Findings
Kim et al. 2006 Evaluate that at lower rotational speed and high
welding speed insufficient heat input is generated
resulting in cavity/ groove like defects

FSW is capable of producing welds with less defects but

still complete elimination of process upset is not possible.

Much researchers has been devoted to understand

the effect of process parameters on defect formation in
order to optimize the process parameters for FSW. Still
optimization of process parameters is mostly done by
trial and error.

In the past few decades, there has been research

going on in the field of MP FSW/ FSP where it is more
desirable to repair the defective portion of the weld than
to throw as a scrap.

One of the technique is to repair the defects is simply

RE-WELDING using nominal process parameter.
Author Year Findings
Brown et al. 2009 Significant reduction in feed force when
welding is done over the previous weld. Grain
size,hardness,temperature remains unaffected with
passes. Gradual reduction of residual stress with
increasing pass number.
Nataka et al. 2006 Reported an improvement in mechanical properties of
Al die casting alloy of MP FSP compared to as-cast BM.
Ma et al. 2006 No effect of overlapping passes on size, aspect ratio or
distribution of Sic particle while performed five pass with
50% overlap FSP on cast A356.
Leal et al. 2008 Used two different alloy. Quality and strength is not just
a function of parameters but also depend on type of
material and condition of treatment.
Surekha et al. 2008 Investigated that MP FSP showed better corrosion
resistance compared to base metal irrespective of
process parameters.

As FSP is one of the technique for grain refinement,

removing flaws,defects,many researchers used MP
FSP to improve the properties of as-cast material.
Author Year Findings
Johannes et
al.
2007 Create large area of super plastic materials with
properties using MP FSP.Grain boundary sliding is the
most important mechanism to achieve super plastic
deformation.
Ma et al. 2009 Two pass FSP resulted in an enhancement in
super plastic elongation with a optimum rate in the
nugget zone of the second pass and a shift to higher
temperature in both central of second pass as well as
transitional zone between passes.
Jana et al. 2010 All single pass runs showed some extent of abnormal
grain growth which was removed with multi-pass.
Higher rotational speed was found to be beneficial for
controlling AGG.
Author Year Findings
Barmouz et al. 2011 Found that MP FSP reduces the Sic particle size,
improve dispersion and separation of Sic particle by
severe stirring action in the NZ.
Ni et al. 2011 MP overlapping FSP transforms the coarse cast
Nab alloy base metal to get defect free fine micro
structure.
Izadi et al. 2012 Study the effect of MP FSP on distribution and
stabilty of carbon nano-tube and to fabricate a MMC
based on Al 5059 and MWCNTs.

Requires less clamping and improves the welding

speed

Improves the weld integrity

Produces further break-up and disposal of oxides

with no loss of mechanical properties

Faster travel speeds

To determine the effect of two contra rotating

FSW tool (Tandem Twin-stir) on the friction stir
processing/welding region of different types of
aluminium alloys.

Fixture design
Pictorial view of fixture (a) Fixture installed over milling
machine bed (b) Welding plates clamped over fixture

Twin tool setup

Twin tool attachment
Contd.

Tool dimension
FSP/FSW tool dimensions
Contd.

Machines used during experiments

Twin tool attachment
Contd.

Work piece size 200 mm x 50 mm x 2.5 mm

Chemical composition (weight %) of work piece material
Si Fe Cu Mn Mg Cr Ni Zn Ti Others, each
Remainder
Aluminium
0.494 .656 .0207 0.0498 0.0045 0.00094 0.0014 < 0.001 0.0265 Max. 0.05% 98.7
Mechanical properties of base metal
Yield Strength in MPa Ultimate strength in MPa Elongation in % age
Hardness at 200 gmf load in
VHN
58.44 97.92 46.08 45-55 HV

Shoulder diameter 16 mm

Pin length 2 mm

Chemical composition (weight %) of Tool

Material SS316
Si P Mn Cr Ni Mo Fe
2.13 0.27 8.95 16.29 0.2 0.14 72.01
FSP/FSW tool dimensions

Rotational speed 4

Total weld - 12
Process parameters Values
Rotational speed (rpm) 900, 1120,1400,1800
Welding speed (mm/min) 16,20,25
D/d ratio of tool 3.2
Pin length (mm) 2
Tool shoulder, D (mm) 16
Pin diameter (mm) 5

Metallographic Observations (Macrostructure Analysis)

Optical microstructure
(LEICA DFC-295)
Variable speed grinder
polisher

Micro hardness
Vickers micro hardness testing apparatus
Contd.

Tensile test specimen

Dimension of the tensile test specimen
Contd.

Tensile properties
(a): Universal Testing Machine (INSTRON) (b):
Specimen mounted over UTM
Contd.

Following weld joints properties were studied:

Macrograph

Micro-hardness

Ultimate tensile strength

Yield strength

% elongation

Joint efficiency

Temperature

Surface appearance
Contd.
Sl. No Rotational
speed
Welding
speed
FSP using single tool FSP using twin tool
1 900 16
2 1120 16
3 1400 16
4 1800 16
5 900 20
Contd.
Sl. No Rotational
speed
Welding
speed
FSP using single tool FSP using twin tool
6 1120 20
7 1400 20
8 1800 20
9 900 25
10 1120 25
Contd.
Sl. No Rotational
speed
Welding
speed
FSP using single tool FSP using twin tool
11 1400 25
12 1800 25
Contd.
Tool Weldin
g speed
Rotation speed
900 mm
Rotation speed
1120 mm
Rotation speed
1400 mm
Rotation speed
1800 mm
Single
tool
16
Single
tool
20
Single
tool
25
Twin
tool
16
Twin
tool
20
Twin
tool
25
Contd.
Average micro hardness of 12 samples and base
metal using single tool as well as twin tool
Contd.
Effect of welding speed on average micro hardness of
FSP zone using single and twin tool
1 2 3 4
38
39
40
41
42
43
44
Single tool
Twin tool
AVERAGE MICRO HARDNESS, SPEED - 16 mm / min
5 6 7 8
38
39
40
41
42
43
44
45
46
47
Single tool
Twin tool
AVERAGE MICRO HARDNESS, SPEED - 20 mm / min
9 10 11 12
41
41.5
42
42.5
43
43.5
44
44.5
45
45.5
Single tool
Twin tool
AVERAGE MICRO HARDNESS, SPEED - 25 mm / min
Contd.
Effect of rotational speed on average micro hardness
of FSP zone using single and twin tool
1 5 9
38
39
40
41
42
43
44
Single tool
Twin tool
AVERAGE MICRO HARDNESS, RPM - 900
2 6 10
39
40
41
42
43
44
45
46
Single tool
Twin tool
AVERAGE MICRO HARDNESS, RPM - 1120
3 7 11
38
39
40
41
42
43
44
45
46
Single tool
Twin tool
AVERAGE MICRO HARDNESS, RPM - 1400
4 8 12
38
39
40
41
42
43
44
45
46
47
Single tool
Twin tool
AVERAGE MICRO HARDNESS, RPM - 1800
Contd.
Effect of welding speed on UTS, YS, Elongation and
joint efficiency of FSP zone using single and twin tool
1S 2S 3S 4S 1T 2T 3T 4T
0
10
20
30
40
50
60
70
80
90
100
110
YS
UTS
ELNG
JointEff.
WELDING SPEED- 16 MM/MIN
5S 6S 7S 8S 5T 6T 7T 8T
0
10
20
30
40
50
60
70
80
90
100
110
YS
UTS
ELNG
JointEff
WELDING SPEED- 20 MM/MIN
Contd.
Effect of welding speed on UTS, YS, Elongation and
joint efficiency of FSP zone using single and twin tool
1 2 3 4 5 6 7 8
45
50
55
60
65
70
75
80
YS-S
YS-T
1 5 2 6 3 7 4 8
45
50
55
60
65
70
75
80
YS-S
YS-T
Contd.
Effect of rotational speed on UTS, YS, Elongation and
joint efficiency of FSP zone using single and twin tool
1S 5S 1T 5T
0
10
20
30
40
50
60
70
80
90
100
110
YS
UTS
ELNG
JointEff
ROTATIONAL SPEED = 900 RPM
2S 6S 2T 6T
0
10
20
30
40
50
60
70
80
90
100
110
YS
UTS
ELNG
JointEff
ROTATIONAL SPEED= 1120 RPM
Contd.
Effect of rotational speed on UTS, YS, Elongation and
joint efficiency of FSP zone using single and twin tool
3S 7S 3T 7T
0
10
20
30
40
50
60
70
80
90
100
110
YS
UTS
ELNG
JointEff
ROTATIONAL SPEED= 1400 RPM
4S 8S 4T 8T
0
10
20
30
40
50
60
70
80
90
100
110
YS
UTS
ELNG
JointEff
ROTATIONAL SPEED= 1800 RPM

Welds made with twin tool shows some higher value of

hardness than the single pass FSP. Maximum hardness value
of 46.36 HV is recorded at 1800 rpm with 20 mm/min welding
speed using twin tool.

Both the YS and UTS decreases with twin tool processing. At

900 rpm and 16 mm/min, the tensile strength is 107.48 MPa
and joint efficiency is 109.8% which is maximum using single
tool. On the other hand with the same parameter using twin
tool exhibits the lowest tensile strength of 90.07 MPa and joint
efficiency of 92.0%

It is also observed that both YS and UTS is more with the

joints fabricated by twin tool at 1800 rpm and 16 mm/min
welding speed than the single tool

Different types of shoulder design to be used to find

out the optimum design for the twin tool experiment

Optimization of process parameter (speed, feed rate,

tilt angle) has to be done for better UTS. Design
of experiment technique should be incorporated
to select the appropriate combination of process
parameters viz. Speed, feed rate and tilting in twin
tool operation

Temperature measurement has to be done

throughout the welding operation by using both
infrared thermograph and thermocouple method

Power consumption during welding (both in

conventional welding as well as using twin tool) has
to be finding out by acquiring the data using power
sensor with Lab view

Comparison has to be done between multi pass

welding and twin tool system
Contd.