82
A. K. Choudhary and R. Jain
thickness. Tool steel with a spiral pin along with a concave featureless shoulder was
employed for joining with a 1.5° tilt angle. Two different tool rotation speed (800 and
1400 rpm) with a constant welding speed of 102 mm/min was defined. At 1400 rpm,
Mg 2 Y intermetallic was observed at the interface of the tool and workpiece. However,
800 rpm resulted in the dissolution of precipitates due to increased strain at the noncontacting region. Dynamic recrystallization resulted in a finer grain size of 2–3 μm
within the SZ of stacked layers. Such fine grain size along with precipitates resulted
in good mechanical properties. The strength of the weld significantly increased to
400 MPa and 17% ductility as compared to base material after subjected to aging.
2.9 Conclusion
FSW is a solid-state welding process and has promising aspects in welding different
materials in various configurations. It is also efficient in joining similar as well as
dissimilar material. Being a solid-state joining process it offers various advantages
such as defects related to solidification is eliminated, higher strength due to finer
microstructure, lower energy etc. The selection of the input process parameter is an
important aspect of efficient welding. The choice of input parameter should lead to
optimum heat generation leading to efficient material flow. FSW finds application in
all sectors of industries starting from aerospace, automobile, electronics etc. Though
FSW can efficiently weld high strength material, tool wear remains one of the major
concerns in that direction. Apart from welding the mechanism of bond formation
during FSW has led to evolution in different variants of the process such as friction
stir processing, spot welding, solid-state additive manufacturing. All of them provide
great versatility in the manufacturing of the component.
References
1. Kah P, Rajan R, Martikainen J, Suoranta R (2015) Investigation of weld defects in friction-stir
welding and fusion welding of aluminium alloys. Int J Mech Mater Eng 10(1)
2. Rao SRK, Reddy GM, Rao KS, Kamaraj M, Rao KP (2005) Reasons for superior mechanical
and corrosion properties of 2219 aluminum alloy electron beam welds. Mater Charact 55:345–
354
3. Pastor M, Zhao H, Martukanitz RP, Debroy T. Porosity, Underfill and magnesium loss during
continuous wave Nd :YAG laser welding of thin plates of aluminum alloys 5182 and 5754.
Weld Res Suppl 207–216
4. Thomas CJ, Nicholas MW, Needham JC Murch MG, Templesmith P, Dawes CJ (1995) Friction
stir butt welding. GB Patent Application 9125978.8, no. US Patent 5460317
5. Nicholas ED (2000) Friction stir welding Da decade on. In: IIW Asian Pacific international
congress. Sydney
6. Dawes CJ, Thomas WM (1996) Friction stir welding for aluminum alloys. Weld 3(75):41–45
7. Threadgill PL, Leonard AJ, Shercliff HR, Withers PJ (2009) Friction stir welding of aluminium
alloys. Int Mater Rev 54(2):49–93
A. K. Choudhary and R. Jain
thickness. Tool steel with a spiral pin along with a concave featureless shoulder was
employed for joining with a 1.5° tilt angle. Two different tool rotation speed (800 and
1400 rpm) with a constant welding speed of 102 mm/min was defined. At 1400 rpm,
Mg 2 Y intermetallic was observed at the interface of the tool and workpiece. However,
800 rpm resulted in the dissolution of precipitates due to increased strain at the noncontacting region. Dynamic recrystallization resulted in a finer grain size of 2–3 μm
within the SZ of stacked layers. Such fine grain size along with precipitates resulted
in good mechanical properties. The strength of the weld significantly increased to
400 MPa and 17% ductility as compared to base material after subjected to aging.
2.9 Conclusion
FSW is a solid-state welding process and has promising aspects in welding different
materials in various configurations. It is also efficient in joining similar as well as
dissimilar material. Being a solid-state joining process it offers various advantages
such as defects related to solidification is eliminated, higher strength due to finer
microstructure, lower energy etc. The selection of the input process parameter is an
important aspect of efficient welding. The choice of input parameter should lead to
optimum heat generation leading to efficient material flow. FSW finds application in
all sectors of industries starting from aerospace, automobile, electronics etc. Though
FSW can efficiently weld high strength material, tool wear remains one of the major
concerns in that direction. Apart from welding the mechanism of bond formation
during FSW has led to evolution in different variants of the process such as friction
stir processing, spot welding, solid-state additive manufacturing. All of them provide
great versatility in the manufacturing of the component.
References
1. Kah P, Rajan R, Martikainen J, Suoranta R (2015) Investigation of weld defects in friction-stir
welding and fusion welding of aluminium alloys. Int J Mech Mater Eng 10(1)
2. Rao SRK, Reddy GM, Rao KS, Kamaraj M, Rao KP (2005) Reasons for superior mechanical
and corrosion properties of 2219 aluminum alloy electron beam welds. Mater Charact 55:345–
354
3. Pastor M, Zhao H, Martukanitz RP, Debroy T. Porosity, Underfill and magnesium loss during
continuous wave Nd :YAG laser welding of thin plates of aluminum alloys 5182 and 5754.
Weld Res Suppl 207–216
4. Thomas CJ, Nicholas MW, Needham JC Murch MG, Templesmith P, Dawes CJ (1995) Friction
stir butt welding. GB Patent Application 9125978.8, no. US Patent 5460317
5. Nicholas ED (2000) Friction stir welding Da decade on. In: IIW Asian Pacific international
congress. Sydney
6. Dawes CJ, Thomas WM (1996) Friction stir welding for aluminum alloys. Weld 3(75):41–45
7. Threadgill PL, Leonard AJ, Shercliff HR, Withers PJ (2009) Friction stir welding of aluminium
alloys. Int Mater Rev 54(2):49–93