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The tool has a circular section except at the end where there is a threaded probe or more complicated flute; the junction between the cylindrical portion and the probe is known as the shoulder. The probe penetrates the workpiece whereas the shoulder rubs with the top surface. The heat is generated primarily by friction between a rotating--translating tool, the shoulder of which rubs against the workpiece. There is a volumetric contribution to heat generation from the adiabatic heating due to deformation near the pin. The
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welding parameters have to be adjusted so that the ratio of frictional to volumetric deformation--induced heating decreases as the workpiece becomes thicker. This is in order to ensure a sufficient heat input per unit length. The microstructure of a friction-stir weld depends in detail on the tool design, the rotation and translation speeds, the applied pressure and the characteristics of the material being joined. There are a number of zones. The heat-affected zone (HAZ) is as in conventional welds. The central nugget region containing the onion-ring flow-pattern is the most severely deformed region, although it frequently seems to dynamically recrystallise, so that the detailed microstructure may consist of equiaxed grains. The layered (onion-ring) structure is a consequence of the way in which a threaded tool deposits material from the front to the back of the weld. It seems that cylindrical sheets of material are extruded during each rotation of the tool, which on a weld cross--section give the characteristic onion-rings. The thermomechanically-affected zone lies between the HAZ and nugget; the grains of the original microstructure are retained in this region, but in a deformed state. The top surface of the weld has a different microstructure, a consequence of the shearing induced by the rotating tool-shoulder. Further details of the process can be found in Joining of Commercial Aluminium Alloys, a paper published in the proceedings of an International Conference on Aluminium (INCAL 2003). The process rapidly went into commercial production and has been tremendously successful in the welding of aluminium and its alloys. The picture below is of a ship containing twenty miles of friction stir welds, the joining done by Friction Stir Link, Inc. and Marinette Marine.
The launch of friction stir welded Littoral Combat Ship, September 2006. Reproduced with the permission of Chris Smith, Friction Stir Link, Inc.
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The Machine
The six photographs below show a typical friction stir welding (FSW) machine. This one is at the Joining and Welding Research Institute (JWRI) of Osaka University, Japan. The photographs are taken with the permission of Professor Hidetoshi Fujii; they can be enlarged by clicking on the thumbnails. The last two photographs are a close-up of the tool, as mounted in the machine.
The Tool
An illustration of some types of tools. Each tool has a shoulder whose rotation against the substrate generates most of the heat required for welding. The pin on the tool is plunged into the substrate and helps stir the metal in the solid state.
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Movies of FSW
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The following movies showing robotic friction-stir welding of complex shapes are reproduced for teaching purposes, with the kind permission of Dr Jorge F. dos Santos, GKSS Forschungszentrum GmbH, Institute for Materials Research, Joining Technology, Max-Planck-Str., D-21502 Geesthacht, Germany. Movie 8 has been provided by Megastir Technologies. Movie 1, Robotic FSW of convoluted surface (MPG format) Movie 2, Robotic FSW of convoluted surface (MPG format) Movie 3, Robotic FSW in vertical position (MPG format) Movie 4, Robotic FSW of magnesium alloy (MPG format) Movie 5, Non-Linear Robotic FSW (MPG format) Movie 6, Non-Planar Robotic FSW (MPG format) Movie 7, Non-Planar Robotic FSW (MPG format) Movie 8, Friction Stir Welding of Steel Pipes (WMV format) FSW at TU Graz
FSW of Steel
Steel can be friction stir welded but the essential problem is that tool materials wear rapidly. Indeed, the wear debris from the tool can frequently be found inside the weld. The process would therefore be used in special circumstances where other welding methods are inadequate. These circumstances have yet to be clarified. There are so many good methods by which steel can be welded. The example below is the FSW of 316L stainless steel. The weld is made by Hitachi of Japan, who have kindly provided the photographs via Professor Hiroyuki Kokawa and Sueng Hwan Park of Tohoku University. Notice that the sample becomes red-hot during welding..
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PDF file of image. Since the tool gets red hot, it is necessary to protect it against the enviroment using a shielding gas. The following movie illustrates the friction stir welding of interstitial-free steel, provided by Hidetoshi Fujii, Osaka University (JWRI), Japan. It takes a while before the plate becomes sufficiently heated to proceed with welding. Movie (13 Mb), showing FSW of steel. A possible use of FSW in the welding of steels is in the context of stainless steels [Klingensmith et al.]. Austenitic stainless steels can easily be welded using conventional arc welding and other processes. However, FSW can offer lower distortion, lower shrinkage and porosity. More important is the avoidance of fumes containing hexavalent chromium which is carcinogenic. In addition, chemical segregation effects associated with welding processes involving solidification are avoided. Such segregation can lead to a degradation of corrosion resistance since electrochemical cells are set up between solute-rich and poor domains.
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The hole at the end is where the operation terminated. Made at Tohoku University, courtesy of Sueng Hwan Park and Professor Hiroyuki Kokawa.
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A section through a friction stir weld made in an Al-Si casting alloy. There are pores indicated in the base metal (BM). HAZ represents the heat affected zone, TMAZ the thermomechanically affected zone, and SN the stir nugget. The photographs in this section have kindly been provided by Professor H. Fujii of JWRI, Japan.
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Optical micrographs showing the microstructure in (a) the base metal; (b) heat-affected zone; (c) the thermomechanically affected zone, where considerable refinement of the silicon has occurred.
Optical micrographs of regions (a), (b) and (c) of the stir nugget. The location of these regions is identified in macroscopic section presented above.
The refinement of silicon and elimination of porosity leads to better mechanically properties in the weld than in the base plates.
Wheels
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At the Metal Industries Research and Development Centre, Taiwan. This is a friction stir welded 5000 series aluminium wheel for a sports car.
Inside view of a friction stir welded 5000 series aluminium wheel for a sports car. The FSW is carried out as a seam weld on a cylinder, followed by the forming operation.
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Schematic of TSW
References
Klingensmith, S., J. N. DuPont and A. R. Marder, Welding Journal, 84 (2005) 77s-85s. Extensive review on recent advances in friction stir welding. Emerging fabrication technologies, by Pedro Miguel Guimares Pires Moreira.
Appendix
The images below have nothing to do with friction stir welding. The first picture shows a hybrid laser-arc process in which both a laser and an electric arc are used to achieve penetration. The other picture shows a massive electron beam welder. Both are located at JWRI, Osaka University.
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Materials Algorithms
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