calculated beforehand based on how long the tool would need to work for that particular

depth. Pin length plays a crucial role in material flow. The effect of tool depth influences the
yield strength and UTS. Greater tool depth increases yield strength and UTS.
Shoulder Diameter: With increasing the diameter of shoulder increases the yield strength
and UTS. This might be because of the increased contact area with the increase of shoulder
diameter and this might be reason for the increase of the high temperature region. Te
temperature distribution under the shoulder becomes more uniform with the increasing
shoulder diameter.

3.3 Applications:
Shipbuilding: Project HILDA is actively looking to market a final expert system of friction
stir welding of steel for European shipbuilding organizations but it is also important to note
that friction stir welding is a commonly used technique for joining aluminum components.
Commercial liners have installed FSW aluminum hull panels. As an example the
Super Liner Ogasawara by Mitsui Engineering and Shipbuilding in Japan stands as the largest
friction stir joined ship in operation. While the joining technique has also been implemented
in to various military fleets for missile containers and armor plating.
Aerospace: A friction stir welding expert system need not only be marketed to shipbuilding
clients. The aerospace industry has also been a large advocate for using friction stir welded
components. For example Boeing, Eclipse and Airbus have all utilized the technique in their
fabrication processes. Boeing in particular adopted the technique early on and have
developed their own welding machinery and applied it to such components like
circumferential fuel tank seals.

Automation: Many world renowned car companies have employed the use of friction stir
welding in a variety of component design, from engine cradles, suspension struts to doors,
boots, bonnets and seating. In addition the range of vehicles employing this is vast: from high
performance supercars like the Ford GT and Audi R8 to innovative roadsters like the Mazda
MX-5 and RX-8 through to the revolutionary Toyota Prius.
Computing: On a smaller scale still Apple have employed the technique in the latest
versions of their iMac personal computers - world renowned for their high performance and
reliability - to attach the back and front casing protecting the internal components.
These are just a few examples of the versatility that friction stir welded components
can offer while being no less efficient than its fusion welded counterparts. Despite such
applications focusing on the use of aluminum alloys, with the help of the research and
development of an expert system by project HILDA, steel components can be successfully
used in the same manner. If HILDA can reach its goal of showing the industrial and
commercial sectors that FSW is viable for steel then a whole new world of possibilities will
open for this technique looking at saving current expenditure on joining processes.
Friction stir welding of aluminum alloys has been cited by many users as a cost-saving
process. This is in part due to the elimination of consumable costs, but is also due to the
ability to make most welds in one or two passes, even in thick