Emerging Friction Stir Welding for Aluminium and its Applications

Abstract

Friction Stir Welding (FSW) was invented by Wayne Thomas at TWI (The Welding Institute), and the first patent applications were filed in the UK in December 1991. FSW offers numerous benefits in the fabrication of all aluminum products. Friction Stir Welding (FSW) has become a major joining process in the aerospace, railway and ship building industries especially in the fabrication of aluminum alloys. The process uses a spinning non-consumable tool to generate frictional heat in the work piece. Heat is generated between the tool and material then mechanically intermixes the two pieces of metal at the place of the join, then the softened metal (due to the elevated temperature) can be joined using mechanical pressure. This paper looks at the review, on friction stir welding process, various welding variables, generation and flow of heat, Microstructural features and material flow during FSW. The study indicates that Friction stir welding is most suitable joining technique for similar and dissimilar aluminum alloy. It is found that weld quality of FSW joint is excellent than other joining process. The estimated thermal profiles are compared with experimental results at similar welding conditions, thus validating the developed heat transfer model.