TABLE OF CONTENTS | INDEX

Sr.No. Content Page No.

1. Introduction 3
1.1 Weld Zone 3
1.2 Advantages of FSW over other welding rocess !
2. Friction Stir Processing "
3. #iterature $eview %
3.1 Process &aria'les in FSW %
3.1.1 Welding or (achine &aria'les. %
3.1.2 )ool varia'les. *
3.1.3 +oint design. 12
3.2 )e,erature -istri'ution and .eat )ransfer in FSW rocess 12
3.3 (aterial flow in FSW 13
3./ Weld (icrostructure and Weld (echanical roerties 1/
3.! -efects in FSW Welds 1/
3.!.1 -efects fro, too hot welds 1!
3.!.2 -efects fro, too cold weld 1!
3." Advantages of contra0rotating FSW tools 1%
3.%
(odelling and oti,i1ation of FSW using statistical ,ethods2 F3
,odel2 and soft co,uting tools.
1%
3.%.1 4sing statistical ,ethod 1*
3.%.2 4sing soft co,uting ,ethod 15
/. 6'7ective of the research wor8 29
!. 3:eri,ental Setu 29
!.1 Fi:ture -esign 29
!.2 (achines;Instru,ents used during e:eri,ents 29
!.3 )win )ool Setu 21
!./ 3:eri,ental Wor8 22
!.! (easure,ents 23
!.!.1 (etallograhic 6'servations <(acrostructure Anal=sis> 2/
!.!.2 (icro hardness 2/
!.!.3 )ensile roerties 2!
". $esults and -iscussion 2"
".1 (acro0grah of 12 sa,les using single tool as well as win tool
2"
".2
Average ,icro hardness of 'ase ,etal and 12 sa,les using single
tool as well as twin tool
2*
".3
)ensile strength2 4)S and ? elongation of 'ase ,etal and 12 sa,les
using single tool as well as twin tool
32
"./ Future wor8
3!
$eferences
3"
1. INTRODUCTION
Friction stir welding is a solid state 7oining rocess which was invented at )he welding
Institute <Ca,'ridge2 4@> in 1551A122B.)he 'asic concet is relativel= si,le which utili1e a
non consu,a'le rotating tool consisting of a concentric threaded tool in and tool shoulder2
as shown in fig01.
FSW roduces a strong ,etallurgical 'ond where the severe lastic defor,ation is caused '=
the tool in that lunges or enetrates into the wor8 iece ,aterial and travels along the weld
line. )he shoulder generates the frictional heat which rides on the surface of the wor8 iece.
)he tool serves three ,ain urosesC <1> .eating of the wor8 iece '= friction and severe
lastic defor,ation. <2> (ove,ent of the ,aterial to roduce the 7oint. <3> Contain,ent of
the hot ,etal 'elow the tool shoulder. As a result2 a solid state 7oint is roduced with no
,elting. Decause of various geo,etrical features on the tool2 ,aterial ,ove,ent around the
in is ver= co,le: A3B.
Fig 1.Sche,atic reresentation of FSW A/B
)he direction where the tool rotation is sa,e as the tool travel direction is the advancing side
of the wor8 iece and where the direction is 7ust oosite is the retreating side. )he FSW
rocess can 'e su'divided into 3 hasesC <1> the lunge hase or the initial eriod. <2> )he
,ain hase or the stead= state eriod. <3> )he ter,ination hase or ter,inal eriod. -uring
lunge hase2 tool in lunges a:iall= into the wor8 iece at a secific rate2 where the
te,erature distri'ution within the welding tool and wor8 iece is esta'lished. 6nce the tool
lunges into the wor8 iece2 the tool starts ,oving along the 7oint line and a stead= state
eriod starts where the te,erature distri'ution is unifor,. -uring the ter,inal eriod2 the
tool is withdrawn fro, the wor8 iece leaving an e:it hole or 8e= hole at the end of the weld.
1.1 Weld Zone -
)hread gill divide the FSW weld 1one into / distinct regionsC the nugget 1one <NZ>2 the
ther,o ,echanical 1one <)(AZ>2 the heat affected 1one <.AZ> and the unaffected 'ase
,etal <D(> A/B.)he nugget is the full= re0cr=stalli1ed area2 which undergoes severe lastic
defor,ation and frictional heating during the rocess and is located at the centre of the stir
1one. )he )(AZ is the 1one 'etween the arent ,etal and the stir 1one. )his 1one ,ainl=
consists of elongated arent ,etal grains that have defor,ed in an uward flowing attern
around the nugget 1one. In )(AZ 1one2 re0cr=stalli1ation does not occur 'ecause of li,ited
defor,ation..AZ is located in 'etween arent ,etal and )(AZ 1one2 which e:eriences a
ther,al c=cle 'ut doesnEt undergo an= lastic defor,ation. In this 1one the grains are si,ilar
to that of 'ase ,etal2 however coarsening of the reciitates occurs. De=ond the .AZ2 'ase
,etal 1one e:ist2 which ,a= have e:erienced a ther,al c=cle fro, the weld 'ut the ,icro
structure and ,echanical roerties is not affected '= the heat inut.
Fig02 Sche,atic cross0section of a t=ical FSW weld showing four distinct 1ones <A> Dase
(etal <D> .eat0affected <C> )her,o0,echanical affected <->Stirred <nugget 1one> A"B.
1.2 Advantae! o" FSW ove# ot$e# %eld&n '#o(e!!-
In contrast to conventional fusion welding2 FSW is a solid state 7oining rocess with no
,elting during the rocess. Poor solidification crac8ing2 orosit= 28issing 'ond2 #a1= S are
the t=ical weld defects of conventional fusion welding rocess which can 'e reduced '=
FSW rocess.FSW is considered to 'e the ,ost significant develo,ent in ,etal 7oining in a
decade and is a F greenG technolog= due to its energ= efficienc=2 environ,ental friendliness
and versatilit=. As co,ared to conventional welding ,ethods2 FSW consu,es considera'l=
less energ=2 no consu,a'les such as cover gas or flu: and no har,ful e,issions are created
during welding2 there'= ,a8ing the rocess environ,entall= friendl=. Further 'ecause FSW
does not involve the use of filler ,etal with no ,elting an= Al allo= can 'e 7oined without
concern for co,ati'ilit= and also dissi,ilar alu,iniu, allo=s and co,osites can 'e 7oined
with eHual ease A%05B.
.ence after two decades of develo,ent2 FSW roves to 'e an i,ortant alternative rocess
in aerosace or aeronautical industries involving alu,iniu, allo=s. .igh 7oining seed2
autogeneous welding2 i,roved ,etallurgical roerties and reduced need for hu,an s8ill
are a,ongst the ,ost i,ortant advantages of FSW in co,arison with conventional fusion
welding ,ethod A192 11B.
FSW can 'e alied to ,ost geo,etrical structural shaes and to various t=es of 7oints such
as 'utt2 la2 )0'utt and fillet shaes A122 13B.)he ,ost convenient 7oint configurations for
FSW are 'utt and la 7oints. Configurations of other t=es of 7oint designs are also alica'le
to FSW which are illustrated in fig03.
Fig03 +oint configuration for friction stir welding <a> SHuare 'utt <'> 3dge 'utt <c> )0'utt 7oint
<d> #a 7oint <e> (ultile #a 7oint <f> )0#a 7oint <g> Fillet 7oint A1/B.
Additional 8e= 'enefits of FSW rocess over fusion welding are su,,ari1ed 'elow A1/B
<1> #ow distortion and shrin8age.
<2> 3:cellent ,echanical and ,etallurgical roerties.
<3> No orosit= and satter.
</> No shielding gas reHuired.
<!> No filler wire reHuired.
<"> #ess surface cleaning is reHuired.
<%> Can a'le to weld 2:::2 !:::2 ":::2 %::: series which are difficult '= fusion welding
rocess.
2. F#&(t&on St&# )#o(e!!&n-
Now a da=s in ,anufacturing sectors suer lastic for,ing is one of the ,ost critical area of
research.A1!01*B.)herefore FSP can 'e used as a generic rocess which ena'ling technolog=
for uniti1ed structuresA15B.Friction stir rocessing is a new develoed techniHue2 which is
another variant of FSW rocess. It is a rocess to ,odif= the ,icro structure where there is
no for,ation of 7oint in these alications.
)he 'enefits of FSP include enhance,ent of ,aterial roerties of cast and wrought ,aterial2
.ealing of flaws and casting orosit=2 ,echanical ,i:ing of the surface and su'surface
la=ers2 grain refine,ent2 ho,ogeni1ation of reciitates in various allo=s and co,osites2
enhance suer lasticit= due to e:cessive lastic flow of ,aterial.
Choi et al <2913> A29B used friction stir rocessing <FSP> to incororate SiC articles into the
,atri: of A3!" Al allo= to for, co,osite ,aterial. Constant tool rotation seed of 1*99
r;,in and travel seed of 12% ,,;,in were used in this stud=. )he 'ase ,etal <D(> shows
the h=oeutectic Al0Si dendrite structure and the ,icrostructure of the stir 1one <SZ> is ver=
different fro, that of the D(.
At this ti,e2 FSP is the onl= solid state rocessing techniHue that has uniHue caa'ilities to
increase the suer lastic strain rate as co,ared to other conventional ther,o ,echanical
rocessing such as rolling2 eHual channel angular e:trusion.
*. L&te#at+#e Rev&e%
*.1 )#o(e!! ,a#&a-le! &n FSW
)here is a co,le: ,aterial ,ove,ent and lastic defor,ation involved in friction stir
welding or rocessing which deends on a nu,'er of rocess varia'les. )he ,ain rocess
varia'les in FSW can 'e su'divided into 3 categoriesC (achine varia'les2 tool varia'les and
other varia'les.
)a'le03.1 ,ain rocess &aria'les in FSW A21B
)ool varia'les (achine varia'les 6ther varia'les
)ool ,aterial
Pin and shoulder dia,eter
Pin length
)hread itch
Shoulder and tool features
Welding seed
Sindle seed
Plunge force
)ool tilt angle
+oint design
(aterial )=e and si1e
Proert= of wor8 iece
,aterial
)=e of fi:ture ,aterial
Further the rocess varia'les are ver= ,uch i,ortant to understand the 7oint roerties
which include fatigue strength2 toughness2 corrosion2 hardness and stress corrosion resistance.
)hese rocess ara,eters affect the weld 7oining through heat generation and dissiation.
*.1.1 Weld&n o# .a($&ne ,a#&a-le!.
A,ong all the ara,eters tool rotation rate <w2 r,> and traverse seed <v2 ,,;,in> are the
,ost i,ortant welding ara,eters in FSW. )he tool rotation results in stirring and ,i:ing of
the ,aterial around the tool in and the traverse seed results in ,ove,ent of ,aterial fro,
the front to 'ac8 and co,lete the welding rocess. .igher tool rotation rate generate higher
te,erature 'ecause of high frictional heating results in intense stirring and ,i:ing of
,aterial. With increase in te,erature there is a frictional couling occur 'etween the tool
surface and wor8 iece. So a ,onotonic increase in heating with increasing tool rotation rate
is not e:ected as the coefficient of friction at interface will change with increasing tool
rotation rate A1B.
Sato et al <2992> A22B also o'served that there is a significant rise of te,erature with rise of
rotational seed.
Peel et al <299"> A23B investigate the effect of changing the rotational and traverse welding
seeds on the tool forces2 ower inut and ther,al histor= throughout the welding c=cle.
)he= o'served that 'oth the torHue and e:tent of ,aterial ,i:ing in the stir 1one disla=s a
,uch stronger deendence on the rotational seed than the traverse seed.
Ce,al (eran <299"> A2/B had done friction stir welding on 'rass lates of 3,, thic8ness
with constant rotational seed and different welding seed. )he= also o'served that at
constant rotational seed 112,,;,in welding seed is the oti,u, ara,eter =ield defect
free weld 7oint with ,a:i,u, 7oint strength.
As er @won et al <2995> A2!B friction stir welding was erfor,ed on !9!2 Al late having
thic8ness of 2 ,, with a wide range of rotational seed and constant traverse seed. )he
results showed that at all the tool rotational seed defects free welds were o'tained. In
addition2 the onion ring structure 'eco,es wider as tool rotation seed is increased and on the
other hand grain si1e decreased with decrease in tool rotation seed.
)he ,echanical and ,icro structural 'ehaviour of dissi,ilar FSW AA"9*20AA292/ with
different welding ara,eters was studied '= Cavalierea et al <2995> A2"B.)he= found that the
'est tensile and fatigue roerties were o'tained for the 7oints with the AA"9*2 on advancing
side and welded with an advancing seed of 11!,,;,in.
As er $odrigues et al <2995>A2%B friction stir welds roduced in 1,, thic8 late of
AA"91"0)/ Alu,iniu, allo= with two different tools were anal=sed and co,ared
concerning the ,icrostructure and ,echanical roerties. For each tool2 the welding
ara,eters were oti,i1ed in order to achieve non0destructive welds. )he welds roduced
were classified as hot and cold welds. )he results o'tained showed that hot welds o'tained
with the ,a:i,u, tool rotational seed and ,ini,u, traverse seed2 have i,roved
,echanical roerties relative to the cold welds and that were in under ,atch condition
relative to the 'ase ,aterial.
As er $a7a,anic8ra, et al <2995> A2*B2 te,erature under the tool was strongl= deend on
the tool rotation rate than the welding seed. )he= also de,onstrated that weld seed could
'e the ,ain inut ara,eter which has the highest statistical influence on the ,echanical
roerties.
A1i1ieh et al <2911> A25B used friction stir rocessing to fa'ricate AZ31;Al263 nano0
co,osite for surface alication. )he= o'served that with higher rotation seed2insite of
finer article cluster2 grain growth was occurred due to higher heat inut and si,ultaneousl=
,ore shattering effect of rotation cause 'etter nano0article distri'ution.
#a8sh,inara=anan et al <2911> A39B develoed friction stir welding window for AA2215 Al
allo=. )he= conclude that the Hualit= of the welding deends on the weld itch or tool
advance er revolution <ratio of welding seed to rotational seed> and can 'e increased '=
increasing the welding seed at constant rotational seed or '= decreasing the rotational
seed at constant welding seed.
*.1.2 Tool va#&a-le!.
)ool geo,etr= is the ,ost influential asect of rocess develo,ent which la=s a critical
role in the ,aterial flow and in turn governs the traverse rate at which it can 'e conducted.
)he FSW tool consists of a in and a shoulder. Contact of the in with the wor8 iece
roduces frictional and defor,ational heating and softens the wor8 ,aterial and on the other
hand contacting the shoulder to the wor8 iece increases the wor8 iece heating and e:ands
the 1one of softened ,aterial and constrained the defor,ed ,aterial. )herefore forward
,otion of the tool roduces loads arallel to the direction of travel which is ter,ed as
)raverse loadC Nor,al load is the load reHuired for the tool shoulder to re,ain in contact with
the wor8 iece.
Fig0/ Sche,atic -rawing of FSW tool A1B
)herefore selection of correct tool ,aterial is also one of the ri,e concerns for roduction
of Hualit= welding. &arious researchers studied the ,echanical and ,etallurgical asects of
welds using different tool ,aterials.
)ool steels is the ,ost co,,on tool ,aterial used in FSW rocess for alu,iniu, allo= A310
3!B.)he advantages to using tool steel as friction stir tooling ,aterial include eas=
availa'ilit=2 low cost2 good ,achina'ilit= and esta'lished ,aterial characteristics.
Colegrove et al A3"B and &a1e et al A3%B used co'alt0nic8el0'ase allo= (P1!5 for friction stir
welding of alu,iniu, allo=.
)ungsten I'ase allo=s have also 'een used '= ,an= researchers in friction stir welding of
coer allo=s2 nic8el alu,iniu, 'ron1e2 titaniu, allo=s and steels A3*0/9B.
)a'le03.2 is a su,,ar= of the current tool ,aterials used to friction stir the indicated
,aterials and thic8nesses which are e:tracted fro, the vast literature sources.
)a'le03.2 Su,,ar= of Current Friction stir welding tool ,aterials A1B
Allo= )hic8ness )ool ,aterial
Alu,iniu,
allo=s
J12
J2"
)ool steel2WC0Co
(P 1!5
(agnesiu,
allo=s
J" )ool steel2WC
Coer and
Coer Allo=s
J!9
J11
Nic8el allo=s2PCDN<a>2)ungsten allo=s
)ool steel
)itaniu, allo=s J" )ungsten allo=s
Stainless steels J" PCDN2)ungsten allo=s
#ow0allo=
steels
J19 WC2PCDN
Nic8el allo=s J" PCDN
In recent =ears several new features have 'een introduced in the design of tools. Several tools
designed at )WI are shown in )a'le03.3.
)a'le03.3 A selection of tool design at )WI A1B
)he whorl and (K0)riflute have s,aller in volu,es than the tools with c=lindrical ins.
)he taered threads in the whorl design induce a vertical co,onent of velocit= that
facilitates lastic flow. )he flute in the (K0)riflute also increases the interfacial area
'etween tool and the wor8 iece2 leading to increased heat generation rates2 softening and
flow of ,aterial. ConseHuentl= ,ore intense stirring reduces 'oth the traversing force for the
forward tool ,otion and the welding torHue A33B.Although c=lindrical2 whorl and )riflute are
suita'le for 'utt welding2 the= are not useful for la welding2 where e:cessive thinning of the
uer late can occur together with the traing of adherent o:ide 'etween the overlaing
surfaces. Flared0)riflute and A0s8ew )ools were develoed to ensure frag,entation of the
interfacial o:ide la=er and a wider weld than in usual for 'utt welding. )he Flared0)riflute
tool is si,ilar to (K0)riflute with an e:anded flute2 while A0s8ew )( tool is threaded
taered tool with its a:is inclined to that of the ,achine sindle. Doth of these tools increase
the swet volu,e relative to that of the in2 thus e:laining the stir region and resulting in a
wider weld and successful la 7oints. (otion due to rotation and translation of the tool
induces as=,,etr= in the ,aterial flow and heating across the tool in.
Aart fro, the tool in design there is a significant i,act of tool shoulder rofile and tool
shoulder feature design on weld Hualit=. &arious tool shoulder features design have 'een used
'= )WI. )hese features increase the a,ount of ,aterial defor,ation roduced '= the
shoulder2 resulting in increased wor8 iece ,i:ing and higher Hualit= friction stir welds.
Following figure consists of scrolls2 ridge r 8nurling2 grooving and concentric circles and
can 'e ,achined on an= shoulder rofile.
Fig0! )ool shoulder geo,etries2 viewed fro, underneath the shoulder A/1B
Sciali et al <299%> A/2B erfor,ed FSW using of three different t=e of shoulder geo,etr=
<scroll and fillet2 cavit=Lfillet2 onl= fillet>.)he= investigated the results on ,icro structural
and ,echanical roerties of friction stir welded "9*2 Al allo=. $esults showed that for thin
sheets2 the 'est 7oint has 'een welded '= a shoulder with fillet and cavit=.
Zhang et al<2911> A/3B used the rotational tool without in using three different tool
configuration0inner concave flute2 concentric circle flute and three siral flute. )he
e:eri,ental results showed that tensile strength and grain si1e attained '= the tool with three
siral flute is ,uch 'etter than '= the other two which can 'e used to 7oin thin late of
alu,iniu, allo=.
Forcellese et al <2912> A//B investigated the effect of tool geo,etr= using two different tool
configuration with different values of shoulder dia,eter2 'oth with and without in. $esults
indicate that '= increasing the shoulder dia,eter2 a strong 'eneficial effect on 'oth ductilit=
and strength value is o'tained using in0less tool configuration with ,ore ho,ogeneous
,icro structure. Further Forcellese and Si,oncini <2912> A/!B investigated the lastic flow
'ehaviour and for,a'ilit= of friction stir welded AZ31 thin sheets o'tained using in0less
tool configuration and co,ared the results with the 'ase ,etal.
Malvao et al <2912> A/"B develoed a stud= which ai,ed was to investigate the influence of
shoulder geo,etr= <one is scrolled and another one a conical shoulder tool> on the for,ation
and distri'ution of 'rittle structures in friction stir welding of alu,iniu, and coer 7oint.
)he author noticed that the nugget of the welds roduced using sa,e rocess ara,eters 'ut
different tool geo,etr= had co,letel= different ,orholog= and inter,etallic content.
As er Malvao et al <2913> A/%B wor8 has 'een done to see the influence of the shoulder
geo,etr= on friction stir welding of 1,, thic8 coer0-.P lates. )he welds were roduced
using three different shoulder geo,etriesC flat2 conical and scrolled. D= var=ing the tool
rotation and traverse seed it was o'served that ,an= defects were roduced for all weld
condition in case of flat shoulder. 6n the other hand scrolled shoulder tool is ,ore effective
than the conical one for the roduction of defect0free welds. .owever 'oth geo,etries
reHuired a ,ini,u, rotational seed to avoid internal defects.
$ecentl= )WI focused on so,e new tool designs to increase the weld s=,,etr= '=
increasing the tool travel seed which increases the volu,e of ,aterial swet '= in0to0in
volu,e ratio A/*2 /5B.D= offsetting the a:is of the in of the sindle2 ratio of volu,e of
,aterial swet '= in0to0in volu,e increased.
Si,ilarl= co,0stir tools co,'ine rotar= ,otion <tool shoulder> with or'ital ,otion <tool in>
to ,a:i,i1e the swet volu,e A!9B.)he inherent as=,,etr= roduced during friction stirring
'= alternating the tool rotation is avoided '= re0stir tool either '= rotar= reversal or '= angular
recirocation A!1B.6n the other hand in dual rotation tools2 the in and shoulder rotate
searatel= at different directions A!2B.
*.1.* /o&nt de!&n.
)he ,ost convenient 7oint configurations for FSW are 'utt and la 7oints. Aart fro, 'utt and
la 7oint configurations2 other t=es of 7oint designs2 such as fillet 7oints are also ossi'le a
needed for so,e engineering alications.
*.2 Te0'e#at+#e D&!t#&-+t&on and 1eat T#an!"e# &n FSW '#o(e!!
In FSW2 heat is generated '= friction 'etween the tool and the wor8 iece via lastic
defor,ation of the ,etal. )he heat generation ,echanis, is influenced '= the weld
ara,eters2 ther,al conductivit= of the wor8 iece2 in tool2 'ac8ing anvil and weld tool
geo,etr=. )he te,erature within and around the stirred 1one influence the ,icrostructure of
the welds2 such as grain si1e2 grain 'oundar= character2 coarsening and dissolution of
reciitates and resultant ,echanical roerties of the welds. )herefore the stud= of
te,erature distri'ution and the resulting heat inut within the wor8 iece ,aterial is ver=
i,ortant during FSW rocess.
.wang and co wor8ers <299*> A!3B e:eri,entall= e:lore the ther,al histories and
te,erature distri'ution within 'utt 7oint welds of "9"10)" alu,iniu, allo=. Four
ther,ocoules of @0)=e with data acHuisition s=ste, connected to a ersonal co,uter
were used to record the te,erature histories during welding. )he different t=es of
ther,ocoule la=out i.e sa,e side and eHual distance2 oosite side and eHual distance and
sa,e side and uneHual distance are devised at different locations on the wor8 iece to
,easure the te,erature distri'ution during welding rocess. )he= concluded that the
te,erature inside the in can 'e regarded as a unifor, distri'ution and that heat transfer
starts fro, the ri, of the in to the edge of the wor8 iece.
*.* .ate#&al "lo% &n FSW
)he FSW rocess can 'e defined as a ,etal wor8ing rocess of five conventional ,etal
wor8ing 1ones. )hese areI 1.Preheat2 2.Initial defor,ation2 3.3:trusion2 /.Forging2 !.Post
heat ; cool down. )he rocess during which these 1ones were roduced in shown in the fig0".
)he reheating 1one2 which is ahead of the in2 the te,erature rises due to the frictional
heating of the rotating tool and adia'atic heating of the defor,ation of ,aterial.)he heating
rate and the e:tent of heating is deter,ined '= the travel seed of the tool and the ther,al
roerties of the ,aterial. As the tool ,ove forward2 the ,agnitude of stress e:ceeds the
critical flow stress and the te,erature increases a'ove the critical te,erature of the
,aterial resulting ,aterial flow. At this oint an initial defor,ation 1one is for,ed. )he
,aterial is forced 'oth uward direction and downward direction at shoulder 1one and
e:trusion 1one resectivel=. 4nder the in2 a s,all a,ount of ,aterial is catured in the swirl
1one where the verte: flow attern e:ists. )he ,aterial flows fro, the front to the rear. )he
width of the e:trusion 1one is defined '= a critical isother, where the ,agnitude of
te,erature and stress is insufficient to allow ,etal flow. Forging 1one is followed '= the
e:trusion 1one. In forging 1one2 the ,aterial fro, the front of the tool is forced to ,ove to
the rear side of the tool where the cavit= is for,ed '= the forward ,ove,ent of the tool
under h=drostatic ressure condition. )he shoulder of the tool hels the ,ove,ent of the
,aterial to the cavit= and also alies a downward forging force. (aterial fro, the shoulder
1one is dragged across the 7oint fro, the retreating side towards the advancing side.
Fig0" <a> (etal flow attern and <'> ,etallurgical rocessing 1ones develoed during friction
stir welding A!/B
Muerra et al <2993>A!!B studied the flow of ,etal during FSW using a fa=ing surface tracer
and a ni' fro1en in lace during welding. )he= o'served that ,aterial is ,oved around the
ni' in FSW '= two rocesses. In first rocess ,aterial on the advancing front side of a weld
enters into a rotational 1one that rotates and advances with the ni'. 6n the other hand
,aterial on the retreating front side of the ni' is entrained and fills in ,aterial on the $S of
the ni' wa8e. )he= further conclude that ,aterial transorted '= these two rocesses has ver=
different ther,o ,echanical histories and roerties.
Further .a,ilton and his co0wor8ers <299*> A!"B roosed a ,odel of ,aterial flow during
friction stir welding. )he= found that weld nugget for,s as surface ,aterial which is
e:truded fro, the retreating side into the region of lastici1ed ,aterial around the FSW in
and under the tool shoulder. )he= further o'served that nugget 1one is the co,'ination of
interleaved la=ers of article0rich and article oor ,aterial.
*.2 Weld .&(#o!t#+(t+#e and Weld .e($an&(al '#o'e#t&e!.
)he ,icrostructure and conseHuent roert= distri'utions roduced during friction stir
welding of alu,iniu, allo=s are deendent on several factors. )he contri'uting factors
include allo= co,osition2 allo=0te,er2 welding ara,eters other geo,etric factors. )he
allo= co,osition deter,ines the availa'le strengthening ,echanis,s and how the ,aterial
will 'e affected '= the te,erature and strain histor= associated with FSW. Si,ilarl= the
welding ara,eters <e.g.2 tool rotation rate and welding seed> dictates for a given tool
geo,etr= and the ther,al 'oundar= conditions2 the te,erature and strain histor= of the
,aterial 'eing welded. Plate gage and other geo,etric factors <such as shoulder si1e2 heat
sin8s associated with cla,ing etc.> ,a= affect the te,erature distri'ution within the weld
1one and through the thic8ness of the welded lates.
In case of FSW;FSP the weld ,icro structure and roert= distri'ution also deends on the
t=e of allo= such as in case of Al allo= is it non0heat treata'le2 heat treata'le <reciitation0
.ardening> allo=s etc.
)he weld nugget is t=icall= descri'ed as the region of the ther,o ,echanicall= affected
1one that has e:erienced sufficient defor,ation at elevated te,erature to undergo re0
cr=stalli1ation. )he two 8e= varia'les that deter,ine the roerties of the ,aterial in the weld
nugget are the ea8 te,erature and the Huenching rate fro, that te,erature.
According to Sato et al.A!%B2the statisticall= re0cr=stalli1ed grain si1e in the nugget region is
deter,ined redo,inantl= '= the ea8 te,erature in the weldN the higher the ea8
te,erature 2the larger the grain si1e. So,e effect of welding seed ,a= also 'e involved2 'ut
'ecause the grain si1e <for static grain growth> is e:onential with te,erature and linear
with ti,e2 the ea8 te,erature will e:ert the do,inant influence.
.owever a wide range of nugget grain si1es can 'e achieved '= ,aniulation of welding
rocess ara,eters. Mrain si1es of the order of 19s of ,icro,eters and less than 1O, have
'een reorted '= Su and et al <2999> A!*B and .ein1 and et al <2992> A!5B.
*.3 De"e(t! &n FSW Weld!
Co,are to fusion welding rocess of alu,iniu, and its allo=2 the FSW does not suffer fro,
ro'le,s such as weld orosit=2 solidification crac8ing or heat affected liHuation crac8ing.
)his is 'ecause in FSW there is no 'ul8 ,elting of the arent ,aterial. .owever o'taining a
defect0free 7oint with good ,echanical roerties is critical for industrial alication. )he
for,ation of defects such as lac8 of enetration2 lac8 of fusion2tunnels2voids2surface grooves2
e:cessive flash2 surface galling2 nugget collase and 8issing 'onds are ,ainl= related due to
i,'alance in ,aterial flow or due to geo,etric factors i.e. rocess ara,eters <tool design2
tool rotation seed2 tool travel seed2 shoulder lunge deth or a:ial force2 sindle tilt angle>
A"9B . )he te,erature 'elow ,elting oint of the arent ,aterial is the ,ain source of lastic
defor,ation of the ,aterial at the 7oint line. -ue to which ,icro structural change li8e re0
cr=stalli1ation2 coarsening and or dissolution of strengthening reciitates2 grain orientation
and growth occurs. )he i,roer rocess ara,eters in FSW giving rise to too hot or too
cold welding condition. )oo cold weld condition is resonsi'le due to insufficient ,aterial
flow and giving rise to defects li8e void for,ation and non'onding. 6n the other hand too hot
weld condition2 giving rise to e:cessive ,aterial flow leading to ,aterial e:ulsion li8e flash
for,ation and the collase of the nugget within the stir 1oneA"1B .
*.3.1 De"e(t! "#o0 too $ot %eld!
)he defects which are generates under such rocessing conditions are visuall= indentified
through the surface aearance of the welded 7oint. )he i,roer ara,eter settings cause
too ,uch ther,al softening. )he surface of the welded 7oint aears to contain 'listers or
surface galling. Further,ore2 e:cessive heat generation can lead to ther,al softening in the
wor8 iece ,aterial 'e=ond the 'oundar= of tool shoulder. )herefore2 the tool shoulder rather
than activel= articiating as a ,ean of ,aterial contain,ent2 it is giving rise to ,aterial
e:ulsion in the for, of e:cessive flash for,ation. )oo ,uch ther,al softening can also lead
to the thinning of the wor8 iece ,aterial. )he wor8 iece ,aterial 'elow the tool shoulder
will reaches a oint where it is no longer a'le to suort the a:ial load laced uon it. Such a
condition during rocessing causes e:cessive flash of the wor8 iece ,aterial. A weld nugget
collase under too hot welding condition is another serious defect in FSW 7oint. It is not
e:ected all the ti,es that increase of tool rotational seed at constant tool travel seed
causes increase in si1e of the weld nugget A"2B.
@i, and et al <299"> A"2B o'served that e:cessive heat inut had generated due to higher
rotational seed with a lower welding seed. As a result large ,ass of flash was e7ected to the
outside due to the softening of the ,etal and also the ti of the ro'e so,eti,es touches the
'ac8ing late.
*.3.2 De"e(t! "#o0 too (old %eld
)oo cold welding conditions result in wor8 hardening of the ,aterial. )his causes the dr= sli
'etween the tool in and the wor8 iece ,aterial. )he lac8 of surface fills or voids and
channel defects are the ,ain defects arising due to insufficient heat generation. )he
insufficient heat generation causes i,roer ,aterial ,i:ing and thus resonsi'le for non0
'onding A"3B.
@i, and their co0wor8ers also evaluate that at lower rotational seed and high welding seed
insufficient heat inut is generated. As a result cavit= or groove0li8e defects are for,ed. A"3B.
3:cluding the defects due to e:cess and insufficient heat inut one ,ore defect is anal=sed '=
@i, and his co0wor8er which is ter,ed as defects due to a'nor,al stirring. For the a'nor,al
stirring defects are for,ed at higher rotational seeds and higher welding seeds. )he= found
that the a'nor,al stirring is caused due to the different te,eratures 'etween the uer art
near the surface and the lower art. -ue to discontinuous flow of ,aterial shae of the to
art on the advancing side in the stir 1one is co,letel= different than the shae due to e:cess
or insufficient heat inut
FSW is caa'le of roducing weld with a ver= less defects 'ut still eli,ination of co,lete
rocess uset is not ossi'le. (uch research has 'een devoted to understanding the effect of
rocess ara,eters on defect for,ation in order to oti,i1e the rocess ara,eters for FSW.
Still oti,i1ation of rocess ara,eters is ,ostl= done '= trial and error.
In ast few decades2 there has 'een research going on in the field of ,ulti0ass welding and
rocessing where it is ,ore desira'le to reair the defective ortion of the weld than to throw
as a scra. 6ne of the techniHues that can 'e used to reair defects arising fro, rocess
usets is si,l= re0welding using the no,inal rocess ara,eter A"/B. Drown et al <2995>
A"!B erfor,ed five overlaing asses and found that there is no need of an= ad7ust,ent for
,ulti ass welding. Further there is a significant reduction in feed force when welding over
the revious weld. .owever grain si1e2 hardness and te,erature during welding is
unaffected with nu,'er of asses. Again there is a gradual reduction of residual stress with
increasing ass nu,'er.
Nata8a et al. <299"> A""B reorted an i,rove,ent in the ,echanical roerties of alu,iniu,
die casting allo= of ,ulti0ass FSP co,ared to the as0cast 'ase ,etals. As co,ared to 'ase
,etal2 hardness increased '= 29.&and the tensile strength of the ,ulti0ass seci,ens were
significantl= increased to a'out 1.%ti,es of as0cast 'ase ,etal. )he ,ain reason for
i,rove,ent of ,echanical roerties is due to the eli,ination of cold fla8e2 unifor,
disersion of the finer Si articles and grain refine,ent of alu,iniu, ,atri:. 6n the other
hand (a et al<299"> A"%B reorted that there is no effect of overlaing asses on si1e2 asect
ratio or distri'ution of the Si article while erfor,ed five0ass with !9? overla FSP on
cast A3"!.
#eal and #ouriero <299*>A"*B investigated the effect of overlaing FSW asses using two Al
allo=s<AA!9*306 and AA "9"30)">.)he= found that the Hualit= and strength of the welds is
not 7ust a function of the welding ara,eter 'ut also deend on the t=e of ,aterial and its
condition of treat,ent. #astl= the= found that weld olishing i,roved the ,echanical
efficienc= of the welded 7oint.
As Friction stir rocessing is one of the ,ost ro,ising techniHues for grain refine,ent2
re,oving flaws2 defects and all2 ,an= researchers used ,ulti0ass friction stir rocessing to
i,rove the roerties of as0cast ,aterial.Fs 'een alied '= +ohannes and (ishra <299%>
A"5B to de,onstrate the effectiveness of ,ultile asses to create large area of suer lastic
,aterials with roerties. )he= conclude that MDS is the ,ost i,ortant ,echanis, to
achieve suer lastic defor,ation. Si,ilarl= (a et al <2995> A%9B noted that two ass FSP
resulted in an enhance,ent in suer lastic elongation with a oti,u, rate in the nugget
1one of second ass and a shift to higher te,erature in 'oth central of second ass as well as
transitional 1one 'etween two asses.
Sure8ha et al <299*> A%1B reorted that ,ulti0ass FSP showed 'etter corrosion resistance
co,ared to the 'ase ,etal.
4sing cast Al allo=2 +ana et al <2919> A%2B reorted that all single ass runs showed so,e
e:tent of a'nor,al grain growth which was re,oved with ,ulti0asses. )he= also e:a,ined
and found that higher rotational seed was found to 'e 'eneficial for controlling the AMM .
Dar,ou1 et al. <2911> A%3B Fa'ricated cu;sic co,osites using (FSP results found that ,ulti
ass FSP reduces the Sic article si1e2 i,rove the disersion and searation of Sic article
'= severe stirring action in the nugget 1one which reduces the grain si1e of the coer ,atri:
and created strong interfacial 'onding '= re,oving the orosit= content.
(P6 FSP has 'een alied '= Ni and et al.<2911> A%/B to transfor, the coarse as0cast Na'
allo= 'ase ,etal to get defect free ,aterial with fine ,icrostructure2 which was feasi'le to
,odif= the large si1ed lates.
Si,ilar t=e of stud= had 'een conducted '= I1adi and Merich <2912>A%!B to stud= the effect
of ,ulti0ass FSP on distri'ution and sta'ilit= of car'on nano0tu'e and to fa'ricate a ,etal
,atri: co,osite<((C> 'ased on A# !9!5 and (WCN)s.
)o avoid the use of ,ulti0ass FSW;FSP2 the two0tool0FSW concet is 'eing develoed at
)WI in several variations and is referred to as )win0Stir A%"2 %%2 and %*B. 6ne of those
techniHues is )ande, twin0stir techniHue. )ande, )win0Stir uses two FSW tools <with or
without counter rotation> ositioned one in front of the other.
*.4 Advantae! o" (ont#a-#otat&n FSW tool!
It is new variant techniHues of FSW;FSP which reHuire less cla,ing and i,rove the
welding seed. With two contra0rotations the resultant force counters each other so that
the arts to 'e welded reHuire relativel= low securing forces.
)he tande, techniHue i,roves the weld integrit= '= disruting and frag,enting the
residual o:ide la=er re,aining within the first weld region '= the follower tool.
As the weld ,ade over the first run2 'ut in reverse direction2 creates no loos of
,echanical roerties 'ut roduces further 'rea80u and disersal of o:ides.
Since the second tool travels over the first weld regionN it does not have to 'e as ro'ust as
the leading tool.
Further the ,otion roduced '= the counter rotating tande, )win0Stir is si,ilar to $e0
stir tool2 'ut the )win stir roduces faster travel seeds and in addition efficienc= of FSW
can 'e i,roved with the use of two FSW tools A111B.
*.5 .odell&n and o't&0&6at&on o" FSW +!&n !tat&!t&(al 0et$od!7 FE
0odel7 and !o"t (o0'+t&n tool!.
In order to accelerate2 suort and guide e:eri,ental develo,ent wor8 with cost Process
,odelling is one of the ,ost innovative techniHues. (odelling 'ased on scientific
understanding of the ,echanis,s and h=sical heno,ena of FSW has great otential for
guiding tool design2 redicting li8el= oerating conditions in new ,aterials or 7oint
geo,etries and then oti,i1ing rocess conditions for ,a:i,u, rocess seed. Further it
hels to redict the occurrence of voids and defects2 the e:tent of ,icro structural and
roert= changes in the defor,ed and heat0affected regions and the develo,ent of residual
stress. Friction stir welding resents a ,ulti h=sics ,odelling challenge2 'ecause it
co,'ines closel= couled heat flow2 lastic defor,ation at high te,erature and
,icrostructure and roert= evolution. All three contri'ute to the rocessa'ilit= of a ,aterial
'= FSW and to the su'seHuent roerties of the weld.
Anal=tical and nu,erical ,ethods each have a role to la= although nu,erical ,ethods
do,inate due to the ower and ease of use of ,odern wor8stations and software.
)he conventional e:eri,ental design techniHues such as regression ,ethod2 resonse
surface ,ethodolog= <$S(> focus ,ainl= on the ,ean of the erfor,ance characteristics2
where as )aguchi ,ethod ta8es the variance into consideration for the ,odel develo,ent.
)hese tools use e:eri,ental data for the ,odel develo,ent..
Soft co,uting techniHues2 such as artificial neural networ8 <ANN>2genetic
algorith,<MA>2fu11= logic<F#> and their co,'inations rovide an alternative solution for
redictive learning2 ,odelling and oti,i1ation of rocess ara,eters for achieving good
weld Hualit=. )hese evolutionar= algorith,s consider the uncertaint= features of the welding
rocesses2 which cannot 'e e:ressed '= ,athe,atical eHuations. )hus2 the= are 'etter as
co,ared to conventional ,athe,atical and statistical techniHues. )hese tools can handle
large nu,'er of data to generate the ,odel and oti,i1e it with a short ti,e san. )hese tools
are also adata'le for incre,ental learning2 ena'ling the ,odels to 'e i,roved
incre,entall= as new data 'eco,e availa'le.
*.5.1 U!&n !tat&!t&(al 0et$od
&arious statistical tools have 'een alied for the ,odelling and oti,i1ation of FSW rocess
with weld ara,eters.
+a=ara,an et al <2995> A*9B anal=sed the effect of rocess ara,eters using full factorial
design techniHue for oti,u, tensile strength. Further the= develoed a ,athe,atical ,odel
using nonlinear regression anal=sis to correlate the rocess ara,eter with ,easured tensile
strength.
Central co,osite -esign with four ara,eters2 five levels and 31 runs are used '=
Sundara, and (uruga, <2919> A*1B to conduct the e:eri,ent on dissi,ilar Al allo= where
five different in rofiles are used to fa'ricate the 7oints. Further resonse surface
,ethodolog= is e,lo=ed to develo the ,odel.
.eidar1adeh et al <2912> A*2B used resonse surface ,ethodolog= 'ased on central co,osite
rotata'le design to develo a ,athe,atical ,odel redicting the tensile strength of friction
stir welded AA"9"10)/ Al allo= 7oints at 5!? confidence interval.
Do18urt <2911> A*3B used )aguchi aroach of ara,eter design to set the oti,u, welding
ara,eter. )he e:eri,ents were erfor,ed using #5 orthogonal arra= ,ethod.
@oilra7 et al <2912> A*/B found out the oti,u, rocess ara,eter with reference to the
tensile strength of the 7oint using )aguchi #1" orthogonal -63 ,ethod.
*.5.2 U!&n !o"t (o0'+t&n 0et$od
Duffa et al <299"> A*!B roosed a continuu, 'ased F3( ,odel which is caa'le of
redicting non0s=,,etric nature of FSW rocess and the relationshis 'etween the tool
forces and the variation in rocess ara,eters. Predicted results are validated '= co,aring
with e:eri,ental data of force and te,erature distri'ution using AA%9%! Al allo= of 3,,
thic8 late. Fro, the si,ulation results it is found that te,erature distri'ution a'out the
weld line is s=,,etric which is due to the resultant of heat generation where rotational seed
of the tool is the do,inant factor than advancing seed. Dut on the other hand ,aterial flow
and effective strain distri'ution is non0s=,,etric a'out the weld line which is controlled '=
'oth advancing and rotating seeds.
68u=ucu et al <299%> A*"B develoed an ANN ,odel to ,a8e a correlation 'etween the fsw
ara,eters of Al late and ,echanical roerties which were o'tained e:eri,entall=. Inut
ara,eter ta8en in this ,odel are weld seed and r, and outut include tensile strength2
=ield strength2 elongation2 hardness of weld ,etal and hardness of .AZ. $esults showed that
the calculated values were in good agree,ent with ,easured one. So the ,odel can 'e used
as an alternative wa= for the calculation of the ,echanical roerties of the welded Al lates
'= FSW ,ethod. Doldsai8han et al <2911> A*%B roosed an innovative algorith, using
discrete flourier transfor, and a ,ultila=er NN.)his aroach used to detect wor,hole
defects and i,ortant feed'ac8 infor,ation a'out weld Hualit= in real ti,e to a control
s=ste, for friction stir welding.
#a:,inara=anan and Dalasu'hra,anian <2995> A**B used 'oth $S( ,ethod and ANN to
redict the tensile strength of friction stir welded AA%935 alu,iniu, allo=. $esults o'tained
through resonse surface ,ethodolog= were co,ared with artificial NN.
.attel et al <2912> A*5B develoed a ste wise ,odelling aroach to co,'ine an in situ weld
si,ulation with a ost welding failure anal=sis. D= using the co,,ercial software ANSPS2 a
ther,o ,echanical ,odel is develoed to redict the ther,all= induced stresses and strain
during welding and finite ele,ent code is used to stud= the lastic flow locali1ation and
failure in a su'seHuent structure anal=sis. )he= o'served that there is a re,ar8a'le influence
of ost welding stress0strain condition when the welded late is su'7ected to tension2 and it is
largest when the seci,en cut in transverse to the weld line.
&el7ic et al A59B develoed a couled ther,o ,echanical ,odel to stud= the te,erature field2
lunge force and lastic defor,ation of AA 292/0)3!1 Al allo= under different rotational
seed during the friction stir welding rocess. )hree di,ensional F3 ,odel has 'een
develoed in ADAQ4S;3KP#ICI) using the ar'itrar= #agrangian03ulerian for,ulation2 the
+ohnson0coo8 ,aterial law and the coulo,'Es law of friction. In this stud=2 the= o'served that
the ,a:i,u, te,erature in the welding rocess is lower than the ,elting oint te,erature
of the 'ase ,etal and the te,erature field is aro:i,atel= s=,,etrical along the line of
welding. With increase of rotational seed2 the lunge force is reduced. )he= further o'served
that the lastic strain is ,ore in the advancing side and even with increase of r,N the low
lastic strain region is on retreating side.
2. O-8e(t&ve o" t$e #e!ea#($ %o#9
)hough the twin stir techniHues was roosed '= )WI2 'ut no detailed research on ,icro
structure2 ,echanical roerties and rocess oti,i1ation has 'een carried out till toda=.
)herefore2 the o'7ective of this wor8 is laced on to deter,ine the effect of two contra
rotating FSW tool <)ande, )win0stir> on the friction stir rocessing;welding region.
In order to de,onstrate the characteristics of twin tool2 a tool s=ste, was designed and used
initiall= for friction stir rocessing. When e:eri,ents was conducted 'oth the tools rotated
indeendentl= 'ut in oosite direction to each other and ass over the sa,le one after
another.
3. E:'e#&0ental Set+'
3.1 F&:t+#e De!&n
For conducting actual e:eri,ents it reHuires a fi:ture which can hold the welding lates
fir,l= and revents the rotar= and translator ,otions. So a roerl= designed fi:ture was
,anufactured and installed over the ,illing ,achine 'ed as shown in figure0 which has
higher da,ing coefficient and shoc8 a'sor'ing caa'ilit=.
Fig0 % Pictorial view of fi:ture <a> Fi:ture installed over ,illing ,achine 'ed <'> Welding
lates cla,ed over fi:ture
3.2 .a($&ne!;In!t#+0ent! +!ed d+#&n e:'e#&0ent!
&F 3.! 8nee t=e vertical ,iiling ,achine has 'een used to fa'ricate the 7oints is shown in
fig0*.)his has a facilt= of $P( ranges fro, !901*99 $P( and traverse seed ranges fro, 1"
to *99 ,,;,in.So a large nu,'er of e:eri,ents '= var=ing the welding seed and $P(.
Fig0* &F 3.! @nee t=e vertical ,illing ,achine.
3.* T%&n Tool Set+'
)he self designed twin tool setu is ,anufactured for FSP;FSW is shown in fig05.)he twin
tool setu was ,ounted over the vertical ,illing ,achine. )he twin tool s=ste, is co,osed
of two tools which are rotating in oosite direction to each other. )he ri,ar= tool is
,ounted on the ,ain shaft and the ,ain shaft is connected directl= with sindle of the
,illing ,achine. )herefore2 the ,ain tool rotates at the sa,e rotational seed and in the sa,e
rotation direction as the sindle during the welding rocess. )he secondar= tool is connected
7ust li8e a cantilever 'ea, with the ri,ar= tool with the hel of gear asse,'l=. )he ower
trans,ission fro, the ri,ar= to secondar= tool is si,ilar to the trans,ission of ower fro,
driver to driven gear2 So that the rotation of the secondar= tool is 7ust oosite to the ri,ar=
tool.
Non0threaded c=lindrical in with non0consu,a'le tool was used to fa'ricate the rocess.
3ach of the FSW tools are laced inside the collet with a collet cover. With the hel of
taered roller contact 'earing2 the gear is asse,'led with the ,ain shaft or the sindle. .ence
when the ,;c ower is on2 the ,ain sindle rotates2 which trans,it ower to the ri,ar= tool
through the driver gear and on the other hand2 the ,ain gear trans,its ower to the driven
gear so that the second tool also rotates si,ultaneousl= with the first tool 'ut in oosite
direction.
Fig05 twin tool attach,ent
3.2 E:'e#&0ental Wo#9
)he rolled lates of 2.! ,, thic8ness2 co,,ercial ure alu,iniu, allo= have 'een cut into
the reHuired si1e <299,,R!9,,R2.!,,> '= ower hac8saw cutting and ,illing. )he 7oint
configuration is o'tained '= securing the lates in osition using ,echanical cla,s. Doth
FSP and FSW were erfor,ed along the longitudinal direction and erendicular to the
rolling direction of the late. Non0consu,a'le tools ,ade of stainless steel SS31" have 'een
used to fa'ricate the 7oints. )he tool di,ensions are shown in fig019.
)he che,ical co,osition and ,echanical roerties of 'ase ,etal are resented in ta'le0!.1
and !.2.)he che,ical co,osition of wor8 iece ,aterial and tool ,aterial was anal=1ed
using 63S anal=sis. )he che,ical co,osition of tool ,aterial is shown in ta'le !.3.Fro,
63S anal=sis it is confir,ed that the tool ,aterial is SS31" t=e. )he tensile seci,en of
'ase ,aterial is also tested to chec8 the ,echanical roerties of the 'ase ,aterial. &ic8ers
,icro hardness test is also erfor,ed to chec8 the ,icro hardness of 'ase ,aterial.
)a'le0!.1 che,ical co,osition <weight ?> of wor8 iece ,aterial
C$e0&(al (o0'o!&t&on <%e&$t => o" %o#9 '&e(e 0ate#&al
S& Fe Cu (n (g Cr Ni Zn )i 6ther
s2
each
$e,ainder
Alu,iniu,
9./5/ ."!" .
929%
9.9/5
*
9.99/
!
9.9995
/
9.991
/
J
9.991
9
9.92
"!
(a:.
9.9!
?
5*.%
)a'le !.2C (echanical roerties of Dase ,aterial
?&eld St#ent$ &n
.)a
Ult&0ate !t#ent$ &n
.)a
Elonat&on &n = ae 1a#dne!! at 2@@ 0"
load &n ,1N
3A.22 5%.52 /".9* /!0!! .&
)a'le !.3C Che,ical co,osition <weight ?> of )ool (aterial SS31"
S& ) .n C# N& .o Fe
2.1* 9.2% *.5! 1".25 9.2 9.1/ %2.91
Friction stir rocessing has 'een carried out 'oth '= using single tool as well as twin tool
attach,ent. )he welding ara,eters and tool di,ensions are resented in ta'le0!./.
)a'le0!./C Welding ara,eters and tool di,ensions
Process ara,eters &alues
$otational seed <r,> 5992112921/9921*99
Welding seed <,,;,in> 1"22922!
-;d ratio of tool 3.2
Pin length <,,> 2
)ool shoulder2 - <,,> 1"
Pin dia,eter <,,> !
Fig019 FSP;FSW tool di,ensions
D= using four rotational seed <5992 11292 1/992 1*99 r,> and three welding seed <1"2 292
2! ,,;,in> total 12 e:eri,ents were erfor,ed 'oth '= single tool and twin tool
attach,ent. )herefore total 2/ e:eri,ents have 'een carried out in this rocess.
3.3 .ea!+#e0ent!
After rocessing2 seci,ens are reared for ,acro and ,icro structural anal=sis2 tensile test
and &ic8erEs hardness test fro, the rocessed region erendicular to the welding direction.
3.3.1 .etallo#a'$&( O-!e#vat&on! <.a(#o!t#+(t+#e AnalB!&!>
(acro structural anal=sis has 'een carried out using a light otical ,icroscoe <#3ICA -FC0
25!> as shown in fig011<a> in cororate with an i,age anal=sing software <#3ICA QWin0&3>
as shown in fig011<'>.)he seci,en for ,etallograhic e:a,ination are sectioned to the
reHuired si1es fro, the 7oint or region co,rising FSP 1one2 ther,o0,echanical 1one2 heat0
affected 1one and 'ase ,etal regions and olished using different grades of e,er= aers.
Final olishing has 'een done using the dia,ond aste in varia'le seed grinder olishing
,achine as shown in fig012 and is etched with @ellerEs reagent to reveal the ,acrostructures.
Fig011 <a> 6tical ,icrostructure <#3ICA -FC025!> <'> #eica QWin0&3 <-isla=>
Fig012 &aria'le seed grinder olisher
3.3.2 .&(#o $a#dne!!
)he ,icro hardness rofiles of the FSW 7oints were ,easured in the cross sections in order to
evaluate the ,aterial 'ehaviour as a function of the different welding ara,eters. (icro
hardness testing was done on &ic8ers ,icro hardness testing aaratus as shown in fig0 13.
)he &ic8ers hardness was ,easured on the olished cross0section with a sacing of 299O,
'etween two ad7acent indentations. )he hardness test was ta8en erendicular to the direction
of welding with testing load of 299g,f and dwell ti,e of 1!sec.
Fig013 &ic8ers ,icro hardness testing aaratus
3.3.* Ten!&le '#o'e#t&e!
)he welded 7oints are sliced using 'and saw and then ,achined erendicular to the welding
direction with a gauge length of 1",, and a width of ",,2 as shown in fig01/ 'elow. )hree
seci,ens were reared and tested for each 7oint and the average is used to esti,ate the
tensile roert=. )he )ensile test was erfor,ed at roo, te,erature using universal testing
,achine <INS)$6N0**"2> as shown in fig01!.the seci,en is loaded at the strain rate of
1.9,,;,in as er AS)( secification so that tensile seci,en undergoes defor,ation as
shown in fig01!<'>.the seci,en finall= fails after nec8ing and the load versus osition has
'een recorded. )he 9.2? offset =ield strengthN ulti,ate tensile strength and ercentage of
elongation have 'een evaluated.
Fig01/ -i,ension of the tensile test seci,en
Fig01! <a> 4niversal )esting (achine <INS)$6N> <'> Seci,en ,ounted over 4)(
4. Re!+lt! and D&!(+!!&on
4.1 .a(#o-#a'$ o" 12 !a0'le! +!&n !&nle tool a! %ell a! %&n tool
In fusion welding of alu,iniu, allo=s2 the defects such as orosit=2 slag inclusion2
solidification crac8s etc deteriorates the weld Hualit= and 7oint roerties. 4suall= friction stir
welded 7oints are free fro, these defects since there is no ,elting ta8es lace during welding
and the ,etals are 7oined in the solid state itself due to the heat generated '= the friction and
flow of ,etals '= the stirring action. .owever FSW 7oints are rone to other defects li8e
void2 tunnel defect2 iing defect2 8issing 'ond2 crac8s etc due to i,roer flow of ,etal and
insufficient consolidation of ,etal in the FSP region. All the 7oints fa'ricated in this
investigation are anal=sed at low ,agnification <19K> using the stereo 1oo, ,icroscoe
<leica QWin &3> to reveal the Hualit= of FSP regions.
)he entire 7oints fa'ricated using twin tool at higher r, and high welding seed are found to
'e free fro, defects. Fro, the ,acrostructure anal=sis it can 'e inferred that for,ation of
defect free FSP 1one is a function of 'oth rotational seed and welding seed used.
)a'le0".1C 3ffect of single tool and twin tool on ,acro structure of the FSP 1ones
Sl.
No
$otational
seed
Welding
seed
FSP using single tool FSP using twin tool
1 599 1"
2 1129 1"
3 1/99 1"
/ 1*99 1"
! 599 29
" 1129 29
% 1/99 29
* 1*99 29
5 599 2!
19 1129 2!
11 1/99 2!
12 1*99 2!
4.2 Ave#ae 0&(#o $a#dne!! o" 12 !a0'le! and -a!e 0etal +!&n !&nle tool
a! %ell a! t%&n tool
)he &ic8ers ,icro hardness values are recorded at different oints of the rocessed 1one for
all the FSP asses using single as well as twin tool. )he first colu,n in the figure disla=s the
average hardness of the 'ase ,etal.
Welds ,ade with twin tool shows so,e higher value of hardness than the single ass FSP.
)his is due to the hardening effect caused '= intense lastic defor,ation in the rocessed
1one. With su'seHuent rocessing of one tool over the other intense lastic defor,ation is
occurred '= which hardness caused due to second ass is ,ore than the first ass.
Fro, the grah it is revealed that the ,a:i,u, hardness value of /".3" .& is recorded
corresonding to 1*99 r, with 29 ,,;,in welding seed using twin tool.
)a'le0 ".2C Average ,icro hardness of 12 sa,les and 'ase ,etal using single tool as well
as twin tool

Fig01" Average ,icro hardness of 12 sa,les and 'ase ,etal using single tool as well as twin
tool
Sa0'le no. U!&n !&nle tool U!&n t%&n tool
BASE.ETAL /5.9%9/! /5.9%9/!
!a0'le-1 /9."5"" /3.*123
!a0'le-2 35.*1*5 /1.99%25
!a0'le-* 3*."59! /3."59"3
!a0'le-2 3*.%"!2 /3.3%/12
!a0'le-3 3*.%%25 35.21"/%
!a0'le-4 /9.!5! /!.29"/5
!a0'le-5 /9.1521 /9./"29%
!a0'le-A 3*.*%! /".3"9*1
!a0'le-C /1./!!! /2.95/2
!a0'le-1@ /1./5 //.2"//
!a0'le-11 /3.55%* /!.393"1
!a0'le-12 /2.*/3/ /3.3/!2
Mrah 103C 3ffect of welding seed on average ,icro hardness of FSP 1one using single and twin tool

Mrah 01 Mrah 0 2
Mrah 0 3
Mrah /0%C 3ffect of rotational seed on average ,icro hardness of FSP 1one using single and twin tool

Mrah I / Mrah I !

Mrah I " Mrah 0 %
4.* Ten!&le !t#ent$7 UTS and = elonat&on o" -a!e 0etal and 12 !a0'le!
+!&n !&nle tool a! %ell a! t%&n tool
)a'le0 ".3 shows all the data corresonding to PS2 4)S and ? of elongation corresonding
to single tool as well as twin tool FSP. It is seen that all the FSP asses ossess higher value
of =ield strength and ulti,ate tensile strength than the 'ase ,etal irresective of using single
or twin tool.
Further it is o'served that 'oth the PS and 4)S decreases with twin tool rocessing. For 599
r, and 1" ,,;,in the tensile strength is 19%./* (Pa which is ,a:i,u, using single tool.
6n the other hand with the sa,e ara,eter twin tool e:hi'it the lowest tensile strength of
59.9% (Pa.
)a'le0".3C PS2 4)S2 ? of elongation and 7oint efficienc= corresonding to single tool as
well as twin tool
$P( Seed )ool PS 4)S
?
3#NM.
+oint
3ff.
D( !*.// 5%.52 /".9* 1
599 1" S 1S %!.%5 19%./* 2%.3 1.95*
1129 1" S 2S %2.52 19".! 2%./1 1.9**
1/99 1" S 3S "!.!3 193./% 3/."2 1.9!%
1*99 1" S /S !9.5! 199.% 33.!2 1.92*
599 29 S !S "9.53 19!.12 3!.!! 1.9%/
1129 29 S "S "!.!5 192."" 2/.%1 1.9/*
1/99 29 S %S "5.%% 19/.3 3!.33 1.9"!
1*99 29 S *S "9.5/ 193.95 2*.%* 1.9!3
D( !*.// 5%.52 /".9* 1
599 1" ) 1) !".2 59.9% 22.9! 9.529
1129 1" ) 2) /!.5" 191.%2 2*.5! 1.935
1/99 1" ) 3) "9.%3 199.%2 39.1% 1.925
1*99 1" ) /) !1./! 193."! 31.25 1.9!5
599 29 ) !) !3.%3 19!./ 3".91 1.9%"
1129 29 ) ") !/.51 199.1! 2".*/ 1.923
1/99 29 ) %) /*.23 19!."" 3!.!3 1.9%5
1*99 29 ) *) !*./1 5%.!/ 1/."3 9.55"
A''reviationsC S S Single tool2 ) S )win tool2 D( S Dase ,etal
Mrah *05C 3ffect of welding seed on 4)S2 PS2 elongation and 7oint efficienc= of FSP
1one using single and twin tool
Mrah 0 *
Mrah 0 5
Mrah 19013C 3ffect of rotational seed on 4)S2 PS2 elongation and 7oint efficienc= of FSP 1one using single and twin tool

Mrah I 19 Mrah 0 11

Mrah I 12 Mrah 0 13
5. F+t+#e Wo#9
)he following studies are reHuired for future wor80
-ifferent t=es of shoulder design to 'e used and to 'e find out which will 'e the
oti,u, design for the twin tool e:eri,ent.
6ti,i1ation of rocess ara,eter <seed2 feed rate2 tilt angle> has to 'e done for 'etter
4)S. -esign of e:eri,ent techniHue should 'e incororated to select the aroriate
co,'ination of rocess ara,eters vi1. Seed2 feed rate and tilting in twin tool oeration.
)e,erature ,easure,ent has to 'e done throughout the welding oeration '= using
'oth infrared ther,ograh and ther,ocoule ,ethod.
Power consu,tion during welding <'oth in conventional welding as well as using twin
tool> has to 'e finding out '= acHuiring the data using ower sensor with #a' view.
After that co,arison has to 'e done 'etween ,ulti ass welding and twin tool s=ste,.
3ffect of distance 'etween the two tools has to 'e anal=sed with the fi:ed distance twin
tool set u.
3ffect of reheating Aonl= frictional heat inut '= the first tool and actual welding done
'= the second tool2 i.e. tool without in and with inB has to 'e one.
-issi,ilar ,aterial with different thic8ness has to 'e weld using twin tool.
3:haustive e:eri,ents are reHuired to get the te,erature and ower data for sa,les
with defect and without defect and which has to 'e i,ort in signal rocessing and to 'e
anal=sed to differentiate.
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"!. Nata8a2@.2 @i,2P.M.2 Fu7ii2..2 )su,ura2).2 @o,a1a8i2).2299".I,rove,entof ,echanical
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"%. #eal.$.(.2#oureiro2A.2 <299*> 3ffect of overlaing friction stir welding asses in the Hualit= of
welds of alu,iniu, allo=s.(aterials and -esign 25 2 5*20551
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suer lastic %9%! Alu,iniu,. (aterials science and 3ngineering A /"/22!!02"9.
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%9. Sure8ha2@.2 (urt=2D.sT2 $ao2@.P.2 299*. (icrostructural Characteri1ation and corrosion
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