Friction Stir Welding: Scope and Recent Development

Abstract

Friction Stir Welding (FSW) is a new solid-state welding technique which finds application in various industries. This chapter introduces the process, basic mechanism, application, and recent research developments. Research work in this book chapter is broadly divided in two parts: experimental-based, and finite element modeling (FEM)-based approaches of the FSW process. In the experimental studies, three recent developments are presented in this chapter: first, a unique twin-tool concept to modify the FSW process and provide alternative to multi-pass FSW; second, feasibility of using ultrasonic coupled with FSW is studied to reduce the amount of force generated during the process and improve the process efficiency; and finally, formability study of friction stir welded blank is presented. Formability of welded blank plays a vital factor for different industrial application, especially in automobile industry. In the second part, FEM method is implemented to simulate the process. Different modeling techniques are also discussed. A case study in each case is presented with sample results, to have a better understanding on the process and development.