Chapter 4
An Application
from a Defect—A Friction Stir
Channeling Approach
Pooja Sarkar, Surjya Kanta Pal, Anandaroop Bhattacharya,
and Barbara Shollock
Abstract This chapter gives an overview of a solid-state welding process, i.e., Friction Stir Welding (FSW) process. The basic principle, usefulness, applications, and
challenges of the process are all described in the chapter. The wormhole defect that
occurs during FSW because of improper process parameter selection leads to the
development of a new cooling channel manufacturing process called the Friction
Stir Channeling (FSC). This chapter gives an extensive idea about the development
of FSC and its capability to replace the conventional heat exchanger manufacturing
processes. The feasibility of the FSC process to produce a continuous cooling channel
is also presented at the end of the chapter through a case study.
Keywords Friction stir welding · Wormhole defect · Friction stir channeling ·
Heat exchanger
4.1 Introduction to Friction Stir Welding (FSW)
Friction Stir Welding (FSW) is one of the most successful and quickly adapted solidstate welding techniques available globally. The acceptance of products after joining
by FSW is much higher than other joining techniques owing to various benefits
P. Sarkar
Advanced Technology Development Centre, Indian Institute of Technology Kharagpur,
Kharagpur 721302, West Bengal, India
e-mail: sarkarpooja90@gmail.com
S. K. Pal (B) · A. Bhattacharya
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur
721302, West Bengal, India
e-mail: skpal@mech.iitkgp.ac.in
A. Bhattacharya
e-mail: anandaroop@mech.iitkgp.ac.in
B. Shollock
King’s College, Strand Campus, Strand, London WC2R 2LS, UK
e-mail: barbara.shollock@kcl.ac.uk
© 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_4
131
An Application
from a Defect—A Friction Stir
Channeling Approach
Pooja Sarkar, Surjya Kanta Pal, Anandaroop Bhattacharya,
and Barbara Shollock
Abstract This chapter gives an overview of a solid-state welding process, i.e., Friction Stir Welding (FSW) process. The basic principle, usefulness, applications, and
challenges of the process are all described in the chapter. The wormhole defect that
occurs during FSW because of improper process parameter selection leads to the
development of a new cooling channel manufacturing process called the Friction
Stir Channeling (FSC). This chapter gives an extensive idea about the development
of FSC and its capability to replace the conventional heat exchanger manufacturing
processes. The feasibility of the FSC process to produce a continuous cooling channel
is also presented at the end of the chapter through a case study.
Keywords Friction stir welding · Wormhole defect · Friction stir channeling ·
Heat exchanger
4.1 Introduction to Friction Stir Welding (FSW)
Friction Stir Welding (FSW) is one of the most successful and quickly adapted solidstate welding techniques available globally. The acceptance of products after joining
by FSW is much higher than other joining techniques owing to various benefits
P. Sarkar
Advanced Technology Development Centre, Indian Institute of Technology Kharagpur,
Kharagpur 721302, West Bengal, India
e-mail: sarkarpooja90@gmail.com
S. K. Pal (B) · A. Bhattacharya
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur
721302, West Bengal, India
e-mail: skpal@mech.iitkgp.ac.in
A. Bhattacharya
e-mail: anandaroop@mech.iitkgp.ac.in
B. Shollock
King’s College, Strand Campus, Strand, London WC2R 2LS, UK
e-mail: barbara.shollock@kcl.ac.uk
© 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_4
131