Chapter 1
Friction Stir Welding
Suman Kalyan Das, Suresh Gain, and Prasanta Sahoo
Abstract Friction stir welding (FSW) is a solid-state joining process which is a
relatively newer technique but has found multiple utility in various industries across
the world. By employing FSW, several issues that conventional fusion welding poses,
viz. distortion, low efficiency, greater heat-affected zone (HAZ), etc., can be avoided.
FSW in fact for some metals gives joint efficiencies near about 100%. FSW has been
highly suitable for welding metals, viz. aluminum and magnesium, which have been
previously found to be highly challenging to be welded by conventional welding techniques. For this reason, FSW has been embraced by aerospace and marine industries
which require welding of large aluminum panels. Joining of dissimilar metals is
one of the interesting aspects that FSW is found to handle quite easily as joining
occurs much below the actual melting temperature of the metals. Research is also
underway for welding metals having high melting points (steel and titanium-based
alloys) using FSW in an efficient manner. FSW however involves higher setup costs
and thus still out of the reach of many small-scale industries which refrain from higher
initial investment. Thus, cost-effective solutions to tackle this issue are continuously
explored by engineers and researchers. With a concerted effort, it is likely that the
true potential of FSW technique would unfold, and it’s benefits reaped by industries
worldwide.
Keywords Friction stir welding · FSW · FSW tool · Solid-state welding
1.1 Introduction
Solid-state welding based on friction heating had been around for some time now.
Friction stir welding (FSW) is a modified version of this technique which is effective
in joining materials and can be joined without reaching their melting point and at the
same time producing an efficient joint. The Welding Institute (TWI), UK, is credited
to have invented this particular welding technology which is considered to be one of
S. K. Das (B) · S. Gain · P. Sahoo
Department of Mechanical Engineering, Jadavpur University, Kolkata 700 032, India
e-mail: skdas.me@gmail.com
© Springer Nature Switzerland AG 2021
J. P. Davim (ed.), Welding Technology, Materials Forming, Machining
and Tribology, https://doi.org/10.1007/978-3-030-63986-0_1
1
Friction Stir Welding
Suman Kalyan Das, Suresh Gain, and Prasanta Sahoo
Abstract Friction stir welding (FSW) is a solid-state joining process which is a
relatively newer technique but has found multiple utility in various industries across
the world. By employing FSW, several issues that conventional fusion welding poses,
viz. distortion, low efficiency, greater heat-affected zone (HAZ), etc., can be avoided.
FSW in fact for some metals gives joint efficiencies near about 100%. FSW has been
highly suitable for welding metals, viz. aluminum and magnesium, which have been
previously found to be highly challenging to be welded by conventional welding techniques. For this reason, FSW has been embraced by aerospace and marine industries
which require welding of large aluminum panels. Joining of dissimilar metals is
one of the interesting aspects that FSW is found to handle quite easily as joining
occurs much below the actual melting temperature of the metals. Research is also
underway for welding metals having high melting points (steel and titanium-based
alloys) using FSW in an efficient manner. FSW however involves higher setup costs
and thus still out of the reach of many small-scale industries which refrain from higher
initial investment. Thus, cost-effective solutions to tackle this issue are continuously
explored by engineers and researchers. With a concerted effort, it is likely that the
true potential of FSW technique would unfold, and it’s benefits reaped by industries
worldwide.
Keywords Friction stir welding · FSW · FSW tool · Solid-state welding
1.1 Introduction
Solid-state welding based on friction heating had been around for some time now.
Friction stir welding (FSW) is a modified version of this technique which is effective
in joining materials and can be joined without reaching their melting point and at the
same time producing an efficient joint. The Welding Institute (TWI), UK, is credited
to have invented this particular welding technology which is considered to be one of
S. K. Das (B) · S. Gain · P. Sahoo
Department of Mechanical Engineering, Jadavpur University, Kolkata 700 032, India
e-mail: skdas.me@gmail.com
© Springer Nature Switzerland AG 2021
J. P. Davim (ed.), Welding Technology, Materials Forming, Machining
and Tribology, https://doi.org/10.1007/978-3-030-63986-0_1
1