Friction Stir Welding of aluminium plate on customized Milling Machine

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✴Friction Stir Welding of aluminium plate on customized Milling Machine


➡Friction-stir welding (FSW) is a solid-state joining process (the metal is not melted) that uses a third body tool to join two facing surfaces. Heat is generated between the tool and material which leads to a very soft region near the FSW tool. It then mechanically intermixes the two pieces of metal at the place of the joint, then the softened metal (due to the elevated temperature) can be joined using mechanical pressure (which is applied by the tool), much like joining clay, or dough. It is primarily used on aluminium, and most often on extruded aluminium (non-heat treatable alloys), and on structures which need superior weld strength without a post weld heat treatment.
➡It was invented and experimentally proven at The Welding Institute UK in December 1991. TWI holds patents on the process, the first being the most descriptive.

✴Working Principle FSW :-

➡A constantly rotated non consumable cylindrical-shouldered tool with a profiled probe is transversely fed at a constant rate into a butt joint between two clamped pieces of butted material.

➡The probe is slightly shorter than the weld depth required, with the tool shoulder riding atop the work surface. Frictional heat is generated between the wear-resistant welding components and the work pieces.

➡This heat, along with that generated by the mechanical mixing process and the adiabatic heat within the material, cause the stirred materials to soften without melting. As the pin is moved forward, a special profile on its leading face forces plasticised material to the rear where clamping force assists in a forged consolidation of the weld.

➡This process of the tool traversing along the weld line in a plasticised tubular shaft of metal results in severe solid state deformation involving dynamic re-crystallization of the base material.


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