Friction stir-welding

Mechanical Engineering Seminar ppt

1. welcome

2. FRICTION STIR WELDING Submitted by Sujith Kumar.C S5 Mech Roll No. 46 Submitted To Anil Kumar. R Lecturer Dept. of Mechanical Engineering N.S.S PTC PANDALAM

3. C O NT E N T S INTRODUCTION PRINCIPLES OF FSW WELDING FSW SET UP MATERIALS USED STRESS – STRAIN GRAPH COMPARISONS ADVANTAGES DISADVANTAGES APPLICATIONS FUTURE DEVELOPMENTS CONCLUSIONS REFERENCES

4. INTRODUCTION • FS W w as invented by W a y ne Tho m as a t T W I ( T h e W elding Institute) Ltd in 1991. • • It overcomes many of the problems associated with conventional joining techniques. FSW is low energy input, capable of producing very high strength welds in wide range of materials at lower cost. • FS W process t a kes place in the solid p hase below the m elting point of the materials to be joined.

5. W E L D I N G Welding is a joining process . Application of heat . With / without application of pressure & electrode. Making permanent joints .

6. CLASSIFICATION OF WELDING Main two classifications are Fusion welding heated to molten state no pressure required eg:Gas welding, Arc welding Plastic welding heated to plastic state pressure required eg:friction welding,forge welding

7. WORKING PRINCIPLE OF FSW FSW a cylindrical, shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two pieces butted together. Frictional heat is generated between the wear resistant welding tool and the material of the work pieces.

8. WORKING PRINCIPLE OF FSW This heat is without reaching the melting point and allows traversing of the tool along the weld line . The plasticized material is transferred the front edge of the tool to back edge of the tool probe and it’s forged by the intimate contact of the tool shoulder and pin profile.

9. EXPERIMENTAL SETUP OF FSW

10. Welding Steel using FSW

11. IMPORTANT WELDING ZONES • F r i c t ion stir w e l d in its cros s - s ection consi s t s of t h ree m ain zones: Nugget, stirred zone, thermo-mechanically affected zone (TMAZ) • (c)heat affected zone (HAZ). T h e t h r ee zones p ose distinct m e chanical p r operties a nd nugget and TMAZ being the weakest part of the joint.

12. Microstructure Analysis Unaffected material Heat affected zone (HAZ) Thermo-mechanical y affected zone (TMAZ) Weld nugget (Part of thermo-mechanical y affected zone)

13. Microstructure analysis Optical micrographs of regions (a), (b) and (c) of the stir nugget.

14. Joint Geometries I t can be used in all positions, Horizontal Vertical Overhead Orbital

15. Material Suitability Copper and its alloys Lead Titanium and its alloys Magnesium alloys Zinc Plastics Mild steel Stainless steel Nickel alloys

16. Tools Parameters H1 3 s te e l t oo l s a re us e d Tool is strong, tough, hard wearing at welding temperatue Have good oxidation resistance, thermal conductivity

17. Common Tools Fixed Pin Tool Self Reacting Pin Tool Adjustable Pin Tool Retractable Pin Tool/Removable type

18. Some of the FSW Machines ESAB SuperStir TM machine FW28 ESAB Machine

19. STRESS VS STRAIN GRAPH

20. Comparison with other joining process FSW vs Fusion Welding Good Mechanical Properties by weld at below MP of work piece Reduced Distortion Reduced Defect Rate Parent Metal Chemistry Simplifies Dissimilar Alloy Welding Eliminates Consumables Reduces Health Hazard &no weld pool

21. A dv a n t a g es Good mechanical properties as in weld condition Improved safety due to absence of toxic fumes No consumables Easily automated on simple milling machines Can operate on all positions (vertical , horizontal ) etc. Low environment impact High superior weld strength

22. Disadvantages Work pieces must be rigidly clamped Slower traverse rate than fusion welding

23. APPLICATIONS AEROSPACE SHIP BUILDING & OFFSHORE AUTOMOTIVE FABRICATIONS RAILWAYS

24. Future Developments Laser-assisted friction stir welding Possible use of induction coil and other mechanism

25. Conclusion FSW opening up new areas of welding daily No distortion , spatter, fumes Welding at below m.p of work piece Good forging action by tool Create high strength weld in hard materials It is alternative to fusion welding

26. REFERENCES [1].M. Jeyaraman, R. Sivasubramanian, V .Balasubramanian “ Optimization of process parameters forfriction stirweldingof cast aluminiuma l oyA319 byTaguchi method ”. Journal of material processing technology 2 (2008)364–372 . [2].P. Hema, S.M. Gangadhar, K. Ravindranath, “ Optimization of Process Parameters for Friction StirWeldingof AluminiumA l oy6061using ANOVA ”. International Journal of Mechanical and Production Engineering,Vol.2, Issue 1 (2012) 36-42. [3] L.Dubourg, A.Merati, M.Jahazi, “ Process optimization andmechanical properties of friction stirlap welds of7075-T6stringerson2024-T3skin ”. The Journal of Materials and design31 (2010) 3324–3330.

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