Friction Stir Welding

A Seminar Report Submitted to the APJ Abdul Kalam Technological

University in partial fulfilment of requirements for the award of degree

Bachelor of Technology
in
Mechanical Engineering
Submitted by
Krishnadas P U
(CCE20ME032)

DEPARTMENT OF MECHANICAL ENGINEERING

CHRIST COLLEGE OF ENGINEERING
IRINJALAKUDA-680 125
December 2023
 CHRIST COLLEGE OF ENGINEERING

VISION
To be a premier technical institution that nurtures professionally competent and socially
responsible engineers through quality technical education, training and research.

MISSION
• Implement state-of-the art teaching-learning practices with qualified faculty and
supportive infrastructure to impart knowledge in modern technology.

• Create a quality education system that encourages faculty and students to involve in
meaningful research for the benefit of society.

• Inculcate leadership qualities, ethical values and foster professionalism with the spirit
of innovation and lifelong learning.
 DEPARTMENT OF MECHANICAL ENGINEERING

VISION
To become a nationally recognized knowledge hub in Mechanical Engineering by moulding
professionally competent and socially responsible engineers.

MISSION
• To create a conducive learning platform for students to excel as professionals through
quality technical education and training.

• To involve students in socially committed projects and programs to broaden their

knowledge and integrity.

• To mould students with good leadership qualities, ethical values and life-long

learning.

Program Educational Objectives (PEO)

1. Apply technical knowledge and skills to find feasible solutions in mechanical
engineering domains and allied industries.

2. Evolve as responsible professionals capable of solving socially relevant problems and

pursue higher education and research.

3. Exhibit professionalism, team work, and ethical attitude through continued learning to
accomplish organisational goals.
 Program Specific Outcomes (PSO)

1. Apply the knowledge of thermal sciences, mechanical design, and manufacturing

principles for analysing and evaluating problems in the domain of Mechanical
Engineering.

2. Apply the knowledge gained through multidisciplinary learning, to solve real-life

problems.

3. Effectively use modern technology tools such as CFD, CAD/CAM and 3-Dprinting in
Mechanical Engineering.
 4. DEPT. OF MECHANICAL
CHRIST COLLEGE OF ENGINEERING IRINJALAKUDA
2023 - 24

CERTIFICATE

This is to certify that the report entitled Friction Stir Welding submitted by Krishnadas P
U (CCE20ME032) in partial fulfilment of the requirements for the award of Degree of
BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING under APJ Abdul
Kalam Technological University.

Mr. Sunil Paul Dr. Arun Augustin

(Seminar Guide) (Project Coordinator)
Asst. Professor Associate Professor
Dept. Of ME Dept. Of ME
Christ College of Christ College of
Engineering, Engineering,
Dr. Sijo M.T
Irinjalakuda Irinjalakuda
Professor and Head
Dept. Of ME
Christ College of
Engineering,
Irinjalakuda
 DECLARATION
I undersigned hereby declare that the seminar report Friction Stir Welding, submitted
for partial fulfilment of the requirements work done by me under supervision of, Dr. Arun
Augustin Associate Professor, Department of Mechanical Engineering, Christ College of
Engineering, Irinjalakuda. This submission represents my ideas in my own words and where
ideas or words of others have been included; I have adequately and accurately cited and
referenced the original sources.
I also declare that I have adhered to for the award of degree of Bachelor of
Technology in Mechanical Engineering of the APJ Abdul Kalam Technological University,
Kerala is a bonafide ethics of academic honesty and integrity and have not misrepresented or
fabricated any data or idea or fact or source in my submission. I understand that any violation
of the above will be a cause for disciplinary action by the institute and/or the University and
can also evoke penal action from the sources which have thus not been properly cited or from
whom proper permission has not been obtained. This report has not been previously formed
the basis for the award of any degree, diploma or similar title of any other University.

Irinjalakuda
Krishnadas P U
15-12-2023
Acknowledgement
First of all, I am indebted to the Almighty God for giving me an opportunity
to excel in my efforts to successfully complete this seminar on time. I would like to
express my deep and sincere gratitude to Dr. Sajeev John, Principal, Christ College of
Engineering and to Dr. Sijo M. T, Head of Department, Department of Mechanical
Engineering, for providing all the required resources for the successful completion of
my seminar.
My heartfelt gratitude also reaches out to Dr. Arun Augustin, Associate Professor,
Department of Mechanical Engineering, for his guidance and constant supervision as
well as for providing necessary information regarding the project and also for the
support in completing the seminar.
I will be failing in duty if I do not acknowledge with grateful thanks to the
authors of the references and other literatures referred to in this seminar. Last but not
the least, I am very much thankful to my parents who guided me in every step which I
took.

Krishnadas P U

i
Abstract

ii
 Contents
Acknowledgement..........................................................................................................................i
Abstract.........................................................................................................................................ii
List of Figures................................................................................................................................iv
List of Tables..................................................................................................................................v
List of abbreviation........................................................................................................................vi
1. Introduction...............................................................................................................................1
1.1 Need for FSW...............................................................................................................................2
1.2 Phases of FSW..............................................................................................................................2
2. Parameters Process Parameters of FSW......................................................................................4
2.1 Tool rotation rate.........................................................................................................................4
2.2 Tool Transverse Speed.................................................................................................................4
2.2 Tool Tilt Angle..............................................................................................................................5
2.3 Tool plunge depth........................................................................................................................6
2.4 Preheating and cooling................................................................................................................6
3. Tools used in FSW.......................................................................................................................7
3.1 Tool Shoulder...............................................................................................................................7
3.2 Tool Probe...................................................................................................................................8
3.3 Types of Tools..............................................................................................................................8
3.3.1 Fixed Probe tool....................................................................................................................9
3.3.2 Adjustable Probe tool...........................................................................................................9
3.3.3 Self-reacting Probe tool......................................................................................................10
4. FSW for various materials.........................................................................................................11
4.1 FSW of Aluminium alloys...........................................................................................................11
4.2 FSW of Non-heat-treatable Al-Alloys.........................................................................................11
4.3 FSW of heat-treatable Al-Alloys.................................................................................................12
4.4 FSW of Magnesium....................................................................................................................12
5. Applications of FSW..................................................................................................................14
5.1 Aerospace Industry....................................................................................................................14
5.2 Marine industry.........................................................................................................................14
5.3 Automotive industry..................................................................................................................15
5.4 Rail Industry...............................................................................................................................15
5.5 Oil Industry................................................................................................................................16
6. Conclusion................................................................................................................................17

iii
References...................................................................................................................................18

List of Figures

iv
List of Tables

v
List of abbreviation

vi
 Chapter 1

Introduction
Friction stir welding (FSW) is a solid-state joining process that uses frictional
heat generated by a rotating tool to join materials. Unlike fusion welding, which melts
the workpiece material, FSW does not melt the material. Instead, the tool generates
heat and friction, which softens the material around it. The tool then moves along the
weld line, stirring the softened material together and creating a strong weld.
FSW was invented in 1991 by The Welding Institute (TWI) in the United Kingdom. It
was initially developed for welding aluminium alloys, but it is now used to weld a
wide variety of materials, including steel, copper, magnesium, and titanium. FSW is a
versatile and efficient welding process that is becoming increasingly popular in a wide
range of industries.
Principles of FSW
The FSW process is based on the principles of frictional heat generation and plastic
deformation. A rotating tool with a threaded or non-threaded pin is plunged into the
joint line of two abutting workpieces. The shoulder of the tool rubs against the surface
of the workpieces, generating frictional heat. The heat softens the material around the
tool, allowing it to flow plastically. The pin then stirs the softened material together,
creating a strong weld.
The FSW process is characterized by the following:
 No melting of the workpiece material: This is a key difference between FSW
and fusion welding. In fusion welding, the workpiece material is melted, which
can lead to defects such as porosity and solidification cracking.
 Low heat input: FSW generates less heat than fusion welding. This results in
less distortion and residual stress in the weld.
 High strength and toughness: FSW welds are typically as strong as the base
material. They are also tough and resistant to cracking.

1
1.1 Need for FSW
1. Overcoming limitations of fusion welding
Fusion welding, while a widely used technique, has certain limitations that FSW
addresses effectively. These limitations include:
 Porosity and solidification cracking: Fusion welding involves melting the base
materials, which can lead to the formation of pores and solidification
cracks, compromising the weld integrity. FSW avoids these issues by not
melting the material, resulting in cleaner and stronger welds.
2. Welding heat-sensitive materials
Fusion welding's high heat input can cause significant distortion and residual stresses
in materials, especially those with low melting points and high thermal conductivity.
FSW's lower heat input minimizes distortion and residual stresses, making it suitable
for welding heat-sensitive materials like aluminium alloys and magnesium alloys.
3. Joining dissimilar materials
Fusion welding often faces challenges when joining dissimilar materials due to
differences in their melting points and thermal conductivities. FSW can effectively
join a wider range of materials, including aluminium alloys, steel, copper, magnesium,
and titanium, without compromising weld quality.
4. Environmental friendliness
Fusion welding generates fumes and smoke, contributing to environmental pollution.
FSW, on the other hand, is an environmentally friendly process as it does not produce
these harmful emissions.
5. Automation and production efficiency
FSW can be readily automated, making it suitable for high-volume production
applications. Automation can improve production efficiency, reduce labour costs, and
ensure consistent weld quality.
1.2 Phases of FSW
FSW mainly consists of 3 phases:
1. Plunging Phase: The plunging phase initiates the FSW process. The rotating
tool, with a threaded or non-threaded pin, is plunged into the joint line between
the two workpieces. The shoulder of the tool rubs against the surface of the

2
 workpieces, generating frictional heat. The heat softens the material around the
tool, allowing it to flow plastically. As a result of the development of heat, the
plasticized metal starts flowing in an upward direction and eventually gets
compressed by the tool shoulder.

2. Dwelling Phase: After reaching the desired depth, the tool rotation is
maintained while the tool traverse motion is paused. This dwell phase allows
the heat generated in the plunging phase to further soften the material around
the tool. The extended heat exposure also facilitates the formation of a strong
weld nugget. The material underneath the tool shoulder is further plastically
deformed and softened by the generated heat due to tool rotation. This is an
optional stage and its duration depends on the requirement of heat generation.

3. Welding Phase: During the welding phase, the tool traverses along the joint
line, stirring the softened material together and creating a strong weld. The
shoulder of the tool continues to generate frictional heat, maintaining the
softened state of the material. The pin continues to stir the material, ensuring
proper mixing and consolidation of the weld nugget.

Fig 1: Phases of FSW

3
 Chapter 2
Parameters Process Parameters of FSW
Process parameters play a crucial role in FSW, influencing the weld quality and
mechanical properties of the joint. The process parameters involved in FSW are Tool
rotation rate, Tool transverse speed, Tool tilt angle, Tool plunge depth and preheating
or cooling. Choosing incorrect process parameters will significantly impact the weld
quality and mechanical properties of the joint. Some of the common weld defects that
can occur due to incorrect process parameters are Porosity, Lack of fusion, Weld
nugget cracking, Underfill and Overfill.
2.1 Tool rotation rate
Tool rotation rate (Clockwise or Anti-clockwise) plays a pivotal role in
generating frictional heat between the tool and the workpiece. As the tool rotates at a
higher speed, it generates more frictional heat due to the increased rubbing between
the tool and the workpiece material. This heat softens the material around the tool,
enabling it to flow plastically and form a strong weld. At higher rotation speeds, the
centrifugal force generated by the rotating tool tends to push the softened material
towards the advancing side of the weld, resulting in a more uniform and cohesive
weld nugget. Slower rotation rate may lead to less effective material mixing and a less
desirable weld structure.
2.2 Tool Transverse Speed
It is defined as the rate at which the rotating tool moves along the joint line
during the welding operation. Tool traverse speed is a critical parameter in the friction
stir welding (FSW) process, influencing the heat input, weld nugget size, and overall
weld quality. Tool traverse speed directly affects the heat input in the FSW process.
Slower traverse speeds allow more time for frictional heat to be generated and
dissipated within the weld zone, resulting in higher heat input. Faster traverse speeds
reduce the time available for heat generation and dissipation, leading to lower heat
input. Weld nugget size, the central portion of the weld that provides the primary

4
strength to the joint, is also influenced by tool traverse speed. Slower traverse speeds
typically result in larger weld nuggets due to the extended exposure to frictional heat.
Faster traverse speeds may lead to smaller weld nuggets due to the reduced heat input.
The selection of tool traverse speed depends on various factors, including the
materials being welded, the desired weld properties, and the specific application
requirements. In general, slower traverse speeds are often preferred for welding
materials with lower thermal conductivities, such as aluminium alloys, while faster
traverse speeds may be more suitable for welding materials with higher thermal
conductivities, such as copper or magnesium alloys.

Material Tool traverse speed range (mm/min)

Aluminium alloys 10-100

Steel 2-40

Copper 40-100

Magnesium 20-60

Table 1: Optimal tool transverse speed for different materials

2.2 Tool Tilt Angle
It is defined as the angle between the axis of the rotating tool and the vertical plane
of the workpiece. It influences the material flow pattern, weld nugget shape, and overall
weld quality of the workpiece. A positive tilt angle, where the tool is tilted towards the
advancing side of the weld, promotes material flow in that direction, resulting in a more
elongated and asymmetrical weld nugget. A negative tilt angle, where the tool is tilted
towards the retreating side of the weld, promotes material flow in that direction, leading
to a more symmetrical weld nugget. The optimal weld nugget shape depends on the

5
specific materials being welded and the desired weld properties. Excessive positive or
negative tilt angles can lead to incomplete fusion, underfill, or overfill defects,
compromising the strength and integrity of the weld. Therefore, careful consideration of
tool tilt angle is essential for optimizing material flow, weld nugget shape, and ultimately,
weld quality. Positive tilt angles are often preferred for welding materials with lower
melting points, such as aluminium alloys, while negative tilt angles may be more suitable
for welding materials with higher melting points, such as steel or titanium.

2.3 Tool plunge depth

It is defined as the depth to which the rotating tool penetrates the joint line during
the welding operation. Tool plunge depth directly affects the heat input in the FSW
process. Deeper plunge depths allow more tool contact with the workpiece material,
resulting in higher frictional heat generation and a larger heat-affected zone (HAZ).
Shallower plunge depths reduce the tool contact area and generate less frictional heat,
leading to a smaller HAZ. Deeper plunge depths typically result in larger weld nuggets
due to the increased heat input and material mixing. Shallower plunge depths may lead to
smaller weld nuggets and potential incomplete fusion defects. The appropriate selection
of tool plunge depth is crucial for achieving the desired weld quality. Excessive plunge
depths can lead to excessive heat generation, overfill defects, and reduced joint strength.
Insufficient plunge depths may result in incomplete fusion defects and reduced weld
strength. In general, deeper plunge depths are often preferred for welding materials with
lower melting points, such as aluminium alloys, while shallower plunge depths may be
more suitable for welding materials with higher melting points, such as steel or titanium.

2.4 Preheating and cooling

Preheating or cooling can also be important for some specific FSW processes. For
materials with high melting point such as steel and titanium or high conductivity such as
copper, the heat produced by friction and stirring may be not sufficient to soften and
plasticize the material around the rotating tool. Thus, it is difficult to produce continuous
defect-free weld. In these cases, preheating or additional external heating source can help
the material flow. On the other hand, materials with lower melting point such as
aluminium and magnesium, cooling can be used to reduce extensive growth of

6
recrystallized grains and dissolution of strengthening precipitates in and around the
stirred zone.

7
 Chapter 3

Tools used in FSW

Friction stir welding (FSW) utilizes frictional heat generated by a rotating tool to
weld materials. The FSW tool is a key component of the process, as it generates the heat
and stirs the softened material to form a strong weld. The tool consists of two primary
components: the pin and the shoulder.

3.1 Tool Shoulder

Tool shoulders are designed to frictionally heat the surface regions of the workpiece,
produce the downward forging action necessary for welding consolidation and constrain
the heated metal beneath the bottom shoulder surface. The shoulder outer surface usually
has a cylindrical shape, but occasionally, a conical surface is also used. Generally, it is
expected that the shape of the shoulder outer surface (cylindrical or conical) has an
insignificant influence on the welding quality because the shoulder plunge depth is
typically small. The diameter of the shoulder is a critical parameter that affects heat
generation, material flow, and weld nugget size. A larger shoulder diameter typically
generates more heat and promotes more material flow, while a smaller shoulder diameter
may be more suitable for welding thin materials or when excessive heat generation is
undesirable.

8
 Fig 3: Types of shoulder surfaces
The above figure shows various shoulder outer surfaces and end surfaces. Of
these, the flat shoulder end surface is the simplest design. The main disadvantage of this
design is that the flat shoulder end surface is not effective for trapping the flowing metal
material under the bottom shoulder, leading to the production of excessive material flash.
To this end, a concave shoulder end surface was designed and has now become popular
for restricting material extrusion from the sides of the shoulder. The concave shoulder
inclines only a small angle from the flat shoulder end surface. During tool plunging, the
material displaced by the probe is fed into tool shoulder cavity. Hence the concave
surface profile of the tool shoulder serves as an escape volume or reservoir for the
displaced material from the probe.

3.2 Tool Probe

The pin is the threaded or non-threaded portion of the rotating tool in friction stir welding
(FSW) that penetrates the joint line and stirs the softened material. It is a crucial
component of the FSW tool, as it plays a significant role in material flow, weld nugget
formation, and overall weld quality. The end shape of the probe is either flat or domed.
The flat bottom probe design that emphasises ease of manufacture is the most commonly
used form. The main disadvantage of the flat probe is the high forge force during
plunging. A round or domed end shape can reduce the forge force and tool wear upon
plunging, increase tool life by eliminating local stress concentration and improve the
quality of the weld root directly at the bottom of the probe. The local surface velocity
coupled with the friction coefficient between the probe and the metal determines the
deformation during friction stirring. The higher surface velocity at the probe edge can
increase its stirring power and hence promote the metal flow under the probe end. The
lowest point of a round bottom probe has a lowest velocity and the least stirring action.

3.3 Types of Tools

There are mainly three types of tools used in FSW:
 Fixed Probe tool
 Adjustable Probe tool
 Self-reacting Probe tool

9
3.3.1 Fixed Probe tool

Fig 4: Fixed Probe Tool

In this type of tools, the tool shoulder and probe are made as a single piece. They
are used to weld workpiece of constant thickness If the probe wears significantly or
breaks, the whole tool must be replaced.

3.3.2 Adjustable Probe tool

Fig 5: Adjustable
Probe tool
The adjustable probe tool consists of an independent probe and shoulder. Since
the probe length can be adjusted this type of tool can be used for welding of variable
thickness.

10
3.3.3 Self-reacting Probe tool

Fig 6: Self- reacting

Probe tool
This type of tool is also called bobbin type tool. This type of tool consists of an
upper shoulder, lower shoulder and probe. This tool can be used for weld of variable
thickness. This tool can only weld perpendicular to the workpiece surface.

11
 Chapter 4
FSW for various materials
4.1 FSW of Aluminium alloys
Aluminium is one of the most used alloys in industries such as Aviation,
Aerospace, Marine and Automotive. Due to its poor weldability Aluminium cannot be
welded using gas welding techniques. FSW has been successfully applied to both non-
heat-treatable and heat-treatable aluminium alloys. FSW in welding aluminium alloys
is attributed to its ability to produce high-quality welds without the formation of
undesirable solidification products, cracking, or porosity. Generally, tool made of
steel is used for friction stir welding of aluminium alloys. 300 – 500 c is achieved
during the welding process
An experimental analysis and optimization of process parameter on friction stir
welding of AA 6061-T6 aluminium alloy using RSM
This paper deals with the experimental analysis of the parameter of FSW using
RSM. Response surface methodology (RSM) is a collection of statistical and
mathematical techniques for optimizing the response of a process in which the
response is a function of several independent variables. The material used in this
investigation is AA6061-T6. The rolled plates of 6 mm thickness were machined to
the required size (100 mm X 50 mm) welding was carried out in butt joint
configuration using friction stir welding machine. The adequacy of the developed
empirical relationship for the response variables UTS, YS and % of Elongation was
tested using the analysis of variance (ANOVA) technique.

12
a b c

13
 The above Figure illustrates the counter plots presenting the interaction effect
of any two input parameters on the UTS where the other parameters are on their centre
level. The increase in tool rotational speed, and tool axial force result in the increase
in UTS of the Friction Stir welded joints up to a maximum value, where the decrease
in welding speed result in the increase in UTS.

a b c

14
 The above figures show the counter plots presenting the interaction effect of
any two input parameters on the YS. It is found that the defects in Weld Zone is
eliminated at higher rotational speed, lower traverse speeds and at larger axial load.

a b c

15
 The above figure shows the response % of Elongation of joints. From graph it
is seen that Increasing the tool rotational speed and axial force, and decreasing the
welding speed lead to elimination of the defects in WZ of the joints due to enough
friction and plastic flow of material and so, the TE is higher.
The main objective of this study was to maximize the UTS, YS and % of
Elongation of Friction Stir welded joints of AA 6061-T6 and also, find the optimum
process parameters from the mathematical model developed. The predicted optimal
results from above technique are UTS,YS and TE that can be obtained, are
197.50MPa,175,25 MPa and 6.96% respectively.
Effect of process parameters on friction stir welding of aluminum alloy 2219-T87

Workpieces in this research were two identical aluminum alloy 2219 plates; measuring
250×50×5 mm. FSW was performed using an adapted vertical milling machine. In
order to measure the process forces, a fixture with load cells, was designed,
developed, and then interfaced to a computer through a DAQ card using
LabVIEW.The selected independent process parameters were tool rotational speed
(N), welding speed(S), shoulder diameter (D), and pin diameter (d).

The above graph shows the downward (Fz) and longitudinal (Fx) forces
that were measured using the experimental setup. The two surges in Fz readings during

16
the pre-welding phase of the process correspond to the start of penetration of the tool
pin and shoulder into the workpieces.
Effect of welding parameters on Fx
The developed empirical model for Fx based on the ANOVA analysis is given below
Fx = 478.2 (N)-0.468 (S)0.646 (D)0.078 (d)0.523

17
 Fig. Effect of process parameters on Fx
The above graph shows the effect of process parameters on Fx. From the
graph it is seen that Fx increase if welding speed, shoulder diameter or pin diameter is
increased and Fx decreases if the tool rotating speed we increased. The empirical
model also denotes the same i.e., Fx is directly proportional to the welding speed,
shoulder diameter and pin diameter and inversely proportional to the tool rotational
speed.

18
 Chapter 5
Applications of FSW
5.1 Aerospace Industry
The aerospace industry has long sought innovative welding techniques to produce
high-strength, lightweight structures for aircraft components. Friction stir welding
(FSW) has emerged as a transformative technology, offering a unique solution to join
aluminium alloys, the primary material used in aircraft structures.
Applications of FSW in Aerospace Manufacturing:
FSW has found widespread application in various aspects of aerospace manufacturing,
including:
 Fuselage panels: FSW is used to join aluminium panels that form the fuselage,
the main body of an aircraft.
 Wings: FSW is employed to weld aluminium components in wing structures,
ensuring strength and integrity.
 Structural frames: FSW is used to join aluminium frames that provide
structural support for aircraft components.
 Fuel tanks: FSW is used to fabricate large aluminium fuel tanks for aircraft.
 Spacecraft structures: FSW is used to join aluminium components in spacecraft
structures, offering lightweight and durable solutions.

5.2 Marine industry

The marine industry demands robust and efficient joining techniques to ensure the
integrity and longevity of marine structures. Fusion welding, the conventional method
for joining metals, involves melting the base material, which can lead to several
drawbacks in marine applications such as Porosity formation, Weld Cracking and
heat-affected Zone degradation. FSW overcomes the limitations of fusion welding by
employing a solid-state joining process. Instead of melting the base material, FSW
mechanically stirs and mixes the softened material, creating a strong bond without the
drawbacks of fusion welding.
Applications of FSW in Marine Structures:
19
  Ship Hulls: FSW is used to join aluminium panels that form the ship hull,
providing strong and corrosion-resistant joints.
 Superstructures: FSW is employed to weld aluminium components in
superstructures, ensuring structural integrity and weight reduction.
 Offshore Structures: FSW is used to join aluminium components in offshore
platforms, providing strong and durable joints for harsh marine environments.
 Marine Equipment: FSW is used to fabricate and repair marine equipment, such as
tanks, pipes, and pressure vessels.

5.3 Automotive industry

The automotive industry is constantly seeking innovative and efficient manufacturing
techniques to produce lighter, stronger, and more fuel-efficient vehicles. The
conventional method for joining metals in automotive manufacturing, involves
melting the base material. This process can lead to several challenges such as
Distortion, Residual stresses and Strength degradation.
Applications of FSW in Automotive Manufacturing:
 Body Panels: FSW is used to join aluminium body panels, improving strength,
weight reduction, and corrosion resistance.
 Frames and Structures: FSW is employed to weld aluminium components in
vehicle frames and structures, ensuring structural integrity and lightweight
construction.
 Powertrain Components: FSW is used to join aluminium components in
powertrain components, such as engine blocks and transmission housings,
providing strength and durability.
 Electrical and Electronics Components: FSW is used to join copper and
aluminium components in electrical and electronics components, maintaining
electrical integrity and reducing weight.

5.4 Rail Industry

The rail industry, responsible for transporting people and goods across vast distances,
demands robust and reliable joining techniques to ensure the integrity and longevity of
rail infrastructure. Fusion welding can result in reduced strength of the rails.
Applications of FSW in Rail Infrastructure:
 New Rail Fabrication: FSW is used to join new rail sections during the
manufacturing process, ensuring strong and reliable welds for new rail tracks.

20
  Rail Repair and Maintenance: FSW is employed to repair and refurbish
damaged rails, extending the service life of existing rail infrastructure.
 Rail Joints and Crossings: FSW is used to weld rail joints and crossings,
providing smooth transitions for trains and reducing wear and tear.
 Switchgear and Special Trackwork: FSW is employed to fabricate and repair
switchgear and special trackwork, ensuring the integrity of critical components
in rail networks.

5.5 Oil Industry

FSW is finding increasing applications in various aspects of oil and gas infrastructure,
including:
 Pipeline Fabrication and Repair: FSW is used to join and repair oil and gas
pipelines, ensuring strong and reliable connections for transporting oil and gas
over long distances.
 Pressure Vessel Fabrication: FSW is employed to fabricate pressure vessels
used for storing and processing oil and gas, providing robust and leak-tight
joints.
 Offshore Platform Components: FSW is used to join aluminium and steel
components in offshore platforms, ensuring structural integrity and corrosion
resistance.
 Subsea Equipment: FSW is employed to fabricate and repair subsea equipment,
such as valves, manifolds, and risers, ensuring the integrity of critical
components in underwater environments.

21
 Chapter 7
Conclusion
In conclusion, friction stir welding (FSW) has emerged as a revolutionary joining
technique with numerous advantages over traditional fusion welding methods.
 FSW offers the ability to produce high-quality, distortion-free welds without
compromising the properties of the base material, making it an ideal choice for
a wide range of applications across various industries.
 FSW's solid-state nature eliminates the drawbacks of fusion welding, such as
porosity formation, weld cracking, and heat-affected zone degradation. This
results in stronger, more durable joints that can withstand harsh operating
conditions.
 FSW's environmental friendliness and versatility further enhance its appeal in
various industries.
 With its continuously advancing technology and expanding applications, FSW
is expected to play significant role in shaping the future of manufacturing and
joining technologies.

22
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