Review on Effect of Process Parameters - Friction Stir Welding Process

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Review on Effect of Process Parameters - Friction Stir Welding Process
S. Boopathi 1, Kumaresan A2, Manohar N3, Krishna Moorthi R4
1,2,3,4, Department of Mechanical Engineering,
Bannariamman Institute of Technology, Sathyamanagalam -638 401.
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The friction stir welding (FSW) process is a
recent solid-state joining process to produce the permanent
joint of two dissimilar metals. In this paper, the study of
experimental the effects of tool rotation speed and welding
speed on the tensile strength, Microstructure, Micro hardness
properties during friction stir welding process. From the
literature, it is understood that tool rotation speed and
welding speed play an important role on the mechanical
properties and weld quality. Important results reported by
various authors are critically reviewed.
Key Words: Friction Stir Welding, mechanical properties,
weld quality, tool rotation speed, axial force and welding
speed.
1.INTRODUCTION
Friction stir welding (FSW) is a solid state joining technique
invented by The Welding Institute (TWI), Cambridge, UK, in
1991. The FSW process uses a, non-consumable cylindrical
tool consisting of a shoulder, and a smallerdiameterprofiled
pin, protruding from the tool shoulder. The rotating tool is
slowly plunged into rigidly clamped work pieces. The
shoulder makes intimate contact with the work piece
surfaces. The pin is completely embedded within the
through-thickness of the work pieces. However, it does not
touch the bottom of the work pieces [1, 2].
It is observed from literature that friction stir welding is
more advantageous such as good weld appearance,improve
strength, ductility, resistance to corrosion, fine grain
structure and welded surface as compare to other welding
techniques. FSW machine consist of non-consumable
rotating tool with probe or pin which is forceddownintothe
joint line where the frictional heatingissufficienttoraisethe
temperature of the material to the range where it is
plastically deformed. Tool rotational speed, welding speed
and tilt angle are the important influencing process
parameters on tensile strength andhardness.Thetraversing
force and side force are not considered as process
parameters and only used for monitoring the process.
Friction stir welding parameters have been selected based
on acceptable mechanical, micro structural, fatigue and
corrosion properties requirement to obtain efficient, defect
free friction stir welded joints.
2. Historical Development of Friction Stir Welding
The frictionstir welding (FSW) processwasinventedin1991
by The Welding Institute (TWI) at Cambridge, in United
Kingdom. It was further developed and was got patented by
the Welding Institute. The first built and commercially
available friction stir welding machines were produced by
ESAB1 Welding and Cutting Products at their equipment
manufacturing plant in Laxa, Sweden. The development of
this process was a significant change from the conventional
rotary motion and linear reciprocating friction welding
processes. It provided a great deal of flexibility within the
friction welding process group [1].
Since 1995 in Europe, Friction Stir Welding has been used in
production applications. The first applications involved
welding of extrusions to form paneling for marine
applications.Sincethen,theprocesshasbeencommercialized
in many other applications, including rail car, automotive,
aerospace, heavy truck, medical applications, etc. Today, the
process is being transitioned into fabrication of complex
assemblies, yielding significant quality and cost
improvements. As the process is maturing, designers are
taking advantage of the process, by designing the product
specifically for the FSW process. The Friction Stir Welding is
apparently quite new welding process as shown in Figure 1
and is a good process for particularly welding aluminum
parts. The conventional rotary friction welding process
requires at least one of the parts being joined to be rotated
and has the practical limitation of joining regular shaped
components, preferably circular in cross-section and limited
in their length. Short tubes or round bars of the same
diameter are a good example.
Figure 1: Mechanism of Friction Stir Welding

3. WORKING PRINCIPLE
3.1 Principle of Operation
In Friction Stir Welding, a cylindrical shouldered tool with a
profiled probe is rotated and slowly plunged into the joint
line between two pieces of sheet or plate material,whichare
butted together. The parts have to be firmly clamped onto
the worktable in a manner that prevents the joint faces from
being forced apart. Frictional heat is generated between the
wear resistant welding tool and the material of the work
piece as shown in Fig. 2 (b). This heat causes the latter to
soften without reachingthe meltingpointandallowspassing
of the tool along the weld line as shown in Fig. 2 (c). The
plasticized material is transferred from the leading edge of
the tool to the trailing edge of the tool probe and is forged by
the intimate contact of the tool shoulder and the pin profile.
It leaves a solid phase bond between the two pieces [3].
Figure 2: FSW Working Processes: (a)Starting position,
(b). Start of joining, (c). Insert joining tool and (d). Joining
[3,5]
3.2 Tool Rotation and Traverse Speeds
There are two tool speeds to be considered in friction-stir
welding; how fast the tool rotates and how quickly it
traverses the interface. These two parameters have
considerable importance and must be chosen with care to
ensure a successful and efficient welding cycle [4]. The
relationship between the welding speeds and the heat input
during welding is complex but, in general, it can be said that
increasing the rotation speed or decreasing the traverse
speed will result in a hotter weld as shown in Figs. 3 (a) and
3 (b).
Another end of the scale excessively high heat input may be
detrimental to the final properties oftheweld.Theoretically,
this could even result in defects due to the liquation of low-
melting-point phases (similar to liquation cracking in fusion
welds). These competing demands leadontotheconcept ofa
processing window: the range ofprocessingparametersthat
will produce a good quality weld. Within this window the
resulting weld will have a sufficiently high heat input to
ensure adequate material plasticity but not so high that the
weld properties are excessively reduced [4,5].
Figure 3: (a) Tool Rotation and (b) Transverse Speed [4]
3.3 Tool Tilt and Plunge Depth
The plunge depth is defined as the depth of the lowest point
of the shoulder below the surface of the welded plate and
has been found to be a critical parameter for ensuring weld
quality. Plunging the shoulder below the plate surface
increases the pressure below the tool and helps ensure
adequate forging of the material at the rear of the tool.
Tilting the tool by 2-4 degrees, such that the rear of the tool
is lower than the front, has been found to assist this forging
process. The plunge depth needs to be correctly set, both to
ensure the necessary downward pressure is achievedand to
ensure that the tool fully penetrates the weld. Giventhehigh
loads required the welding machine may deflect and so
reduce the plunge depth compared to the nominal setting,
which may result in flaws in the weld. On the other hand, an
excessive plunge depth may result in the pin rubbing on the
backing plate surface or a significant under match of the
weld thickness compared to the base material. Variableload
welders have been developed to automatically compensate
for changes in the tool displacement while The Welding
Institute (TWI) has demonstrated a roller system that
maintains the tool position above the weld plate [6].
3.4 Advantages and Disadvantages
The solid-state nature of FSW immediately leads to several
advantages over fusionweldingmethodssinceanyproblems
associated with cooling from the liquidphaseisimmediately
avoided. Problem such as porosity, salute redistribution,
solidification cracking is not a problem during FSW.
Advantages:
 Good mechanical properties in the as welded
condition

 we could weld metal without meltingit,maintaining
its original properties despite the joining process
 we could weld together metals those previously
could not be joined
 No consumables - conventional steel tools can weld
over 1000m of aluminum and no filler or gas shield
is required for aluminum.
 Welding Preparation not usually required
 Low environmental impact (nofumes)andlowheat
distortion
 No filler wire required
Disadvantages:
 Exit hole left when tool is withdrawn.
 Large down forces required with heavy-duty
clamping necessary to hold the plates together.
 Less flexible than manual and arc processes
(difficulties with thickness variations and non-
linear welds).
 Often slower traverse rate than some fusion
welding techniques although this may be offset if
fewer welding passes are required.
 Critical tolerances.
 High investment.
4. EFFECT OF TOOL ROTATION SPEED
4.1. Tensile Properties
The tensile properties of the Aluminium alloy joints made
with different welding conditions resulted in lowest tensile
strength and ductility at lowest spindle speed for a given
traverse speed. As the spindle speed increased, both the
strength and elongation improved, reaching a maximum
before falling again at high rotational speeds. At the
optimum spindle speed, for a given traverse speed, the
ductility of the nugget zone material was considerably
greater than the parent alloy (18-24% compared to ~12%).
[7]. In friction stir welding of AA1050 Aluminium alloy, the
tensile strength decreased with increasing rotation speed
and the elongation increased to a level similar to that for the
base material, when the rotation speed was greater than
1000 rpm (Figure 2.1) [8].
The strength decreased with the increase in
rotational speed regardless of the feed rate. The increase in
strength with the decrease in the rotation speed was most
likely to be due to the decrease in grain size at low rotation
speed [9]
Figure 4. Effect of rotational speed on tensile properties
[8]
Cavaliere et al. studied the effect of welding parameters on
mechanical properties of AA6056 and found thatthehighest
values of material ductility at the welding speeds of 40 and
56 mm/min and the lowest rotating speed. Ductility was
decreased strongly as the rotating and the welding speeds
were increased. The very different mechanical behavior of
the FSW joints was also demonstrated by the strong
variation in grain size and distribution [10].
4.2. Microstructure
Ma et al studied the effect of friction stir processing
(FSP) on microstructure of cast A356 Aluminium alloy and
found that FSP parameters had a significant effect on the
macrostructure of the stirred zone. The lower tool rotation
rates (300-500 rpm) produced a basin-shaped nuggetwitha
wide top region. With increasing tool rotation rate, the
nugget changes from the basin shape to elliptical. There was
a macroscopically visible banded structure. The banded
structure is characterized by a low density of coarse Si
particles [11]. Increasing the tool rotation rate or the tool
rotation-rate/traverse-speed ratioresultedinincreasing the
grain size in the processed zone. It indicated that the high
tool rotation rate breaks up the Si particles and improved
material mixing.
Jariyaboon et al reported that rotation speed
affected the grain size in the nugget region of friction stir
welded AA2024–T351. At a fixed travel speed,anincreasein
rotation speed increased the grain size due to the higher
heat input. At fixed travel speed, a higher rotation speed
created more fragmented particles while at fixed rotation
speed, the travel speed had little or no influence on the
fragmentation of particles [12].
The rotational speed appears to be the most significant
process variable since it also tends to influence the
translational velocity. This was due in part to a slightly
elevated temperature difference at 800 rpm in contrast to

400 rpm tool rotation speed, which promoted grain growth
[13].
The variation in appearance and volume fraction of the
second phase particles of AA7010 alloywereinvestigated by
Hassan et al (2002). As the rotational speed increased, the
temperature within the nugget became higher and more
uniform, as a result the volume fraction of coarse second
phase particles decreased at different positions within the
nugget zone region [14].
Grain growth drastically occurred at
recrystallization temperature (> 0.5Tm, Tm being the
absolute melting temperature) so that the grain growth in
AA1050 alloy stir zone was promoted by an increase in
process temperature or a decrease in cooling rate. The
process temperature increased with increasing rotation
speed of the welding tool [15].
Attallah et al (2004) evaluated mechanical and micro
structural properties of friction stir welded AA2095
Aluminium alloy. They opined that weld nugget grain size
depends on the welding parameters, where the grain size
was found to increase with the increase of the tool rotation
speed, since the heat input increased [16].
Won Bae Lee et al observed that the temperature of
the stir zone in friction stir welded AA6005 alloys ranges
from 458C to 480C.These temperaturesweresufficientto
completely dissolve all precipitates and the cooling rate was
sufficiently rapid to retain alloying elements in saturated
solid solution. Precipitates were not observed in the stir
zone, as a result of dissolution [17].
Scialpi et al analyzed the microstructural featuresof
friction stir welded AA 6082-T6 Aluminium alloy and
observed noticeable microstructure changes. Micrographs
revealed that deformation in the TMAZ resulted in severe
bending of grain structure. In this zone grain shape and
dimensions evolution was quite evident [18].
Ying Chun Chen et al investigated friction stir
welding of AA2219 Aluminium alloy and found that the
metastable precipitates were dissolved and solutionized in
the Aluminium matrix during FSW, but the stable
precipitates were remained and prone to segregate in the
high-strain region, thus resulting in visible bandsofhighand
low particle density. Such visible bands form so-called
“onion ring”- like morphology in the 2219-T6 weld.
However, for 2219-O base metal, the precipitatesexistinthe
form of stable state, and the number was large. So, large
numbers of particles conceal the feature of the “onion ring”-
like morphology in the 2219-O weld [13] .
Rodriguez et al (2005) studied the effect of FSW on
commercial cast aluminum alloys A319 & A413 and found
that the micro-dendritic cell structure of A319 was
completely altered in the remixed FSW zone. Si plates and
needles of A413 were largely brokenandredistributedin the
FSW zone. There is no apparent weld zone degradation[20].
4.3. Micro hardness
The hardness of the friction stirweldedAA5083stir
zone decreased with increasing rotation speed.Theincrease
in grain size led to the lower hardness value of the stir zone
that was produced at the higher rotation speed [15].
Won Bae Lee et al investigated the FSW joints of
AA6061 Aluminium alloy and they observed that the
hardness of the stir zone increased with the tool rotation
speed. A higher tool rotation speed resulted in the lower
cooling rate because stir zone reached a higher temperature
[17].
In friction stir welded AA7010 Aluminium alloy,
when the spindle speed wasincreased,thehardnesslevelsat
the base of the weld increased more rapidly than at the top,
so that the hardness values converge at high spindle speeds
[7].
FSW joints of AA2024 Aluminium alloy had nearly
constant hardness values within the nugget region and very
low on the retreating side than on the advancing side. The
minima were located at transverse locations that were
approximately on a line drawn from the shoulder radius on
the crown to the pin radius at the root of the weld [20].
The hardness profile in the age harden Aluminium
alloy AA6063 stronglydependedonprecipitatedistributions
rather than on grain size. The minimum hardness region
contained only a low density of rod-shaped precipitates,
which led to the minimum hardness in that region
accompanied by a loss of solute from the matrix. No
precipitates could be detected in the softened regions
because of dissolution ofall precipitatesduring welding[15].
Friction stir welded AA 2024 joints exhibited a W-
shaped hardness distribution thatischaracteristicoffriction
stir welds in precipitation hardening aluminum alloys, the
weld nugget was significantly harder than the thermos-
mechanically affectedregion immediatelyoutsidethenugget
boundary A quite strong local softening of the AA7075 - T6
occurred because of the thermal action of the welding
process [16].
In A319, micro hardness values of stir zone were
higher than as cast metal. In A356, micro hardness values of
stir zone were lower than as cast metal. These results show
that the thermos mechanical treatment cycle of the friction
stir processing had a hardening effect in A319 and a slight
softening effect in A356 [21].

5. EFFECT OF WELDING SPEED
5.1 Tensile properties
As the welding speed increased, the width of the strained
region and the value of the maximum strain decreased. The
location of the maximum strain gradually moved to the
retreating side from the advancing side of the joint (Figure
5). In other words, the fracture location of the joint made by
AA1050 Alumiunium alloy gradually changed to the
retreating side from the advancing side of the joint as the
welding speed was gradually increased. The results
described above indicated that the welding speed had a
significant effect on the tensile properties and fracture
locations of the joints [22].
Figure 5 Effect of welding speed on mechanical properties
The ultimate tensile strength ofAA5083 Aluminium
decreased significantly when the traverse speed was
increased. It was found by Peel et al that voids were formed
due to poor consolidation of theweldinterfacewhenthetool
traveled at higher traverse speeds, and hence lower heat
inputs [23].
The tensile strength of as welded 6005 Aluminium alloy had
a proportional relationship with welding speed (Won Bae
Lee et al). Higher welding speeds were associated with low
heat inputs, which resulted in faster cooling ratesofAA5083
friction stir welded joint [17].
Colligan et al investigated the friction stir welded joints of
AA 2519 alloy and the tensile results showed the
progression in the transverse weld tensile strength, yield
strength and elongation respectively, as a function of travel
speed. Welds produced at higher speeds had tensile
fractures in the stir zones, although tensile strengths were
the highest observed and ductility was also high [24].
The tensile properties and fracture location of the
joints were dependent on the micro hardness distributions
and the weld defects of the joints. When the welding speed
was slower than a certain critical value, the FSW produced
defect-free joints. When the welding speed was faster than
the critical value, welding defects were produced in the
joints [25].
Ren et al studied the effect of welding parameters on tensile
properties of friction stir welded Al-Mg-Si alloy and found
that the increase in the traverse speed from 100 to 400
mm/min increases significantly the yield and tensile
strengths of the FSW joints irrespective of the tool rotation
rate [26].
Lee et al studied the friction stir welded A356 alloy and
found the transverse tensile strength and yield strength of
the friction-stir welded joints show the constant and almost
same values in comparison to that of the BM regardless of
welding speed. Sound joints were acquired below 187 mm
/min welding speed [27].
5.2 Microstructure
The nugget region of friction stir welded AA2024-T35
showed a grain structure on a transverse vertical cross-
section that was nearly uniform, with transitions to the base
metal microstructure on both the advancing and retreating
sides. In all cold, medium and hot welds, the transition was
more abrupt on the advancing side of the weld. The mean
grain size in the weld nugget decreased with increasingheat
input. Based on results, it was inferred that the post welding
nugget grain size variation was the result of a complex
combination of static and dynamic re-crystallization and
recovery processes [20]
Yutaka Sato et al investigated the effect of speed on
microstructure and they inferred that the base material had
an elongated coarse grain structure, while the stir zones
consisted of equated grain structures. Grain size in the stir
zone increased with an increase in heat input during FSW
[16].
5.3 Micro hardness
Peel et al investigated the friction stir welding of
AA5083 alloy and observed significant amount of softened
material with the 50% reduced hardness around the weld
line [23].
Liu et al observed a softened region occurred in the
joints and was located at the weld zone and HAZ, and hence
the tensile properties of the joints were lower than those of
the base material. There was a minimum hardness zone on
the advancing side of each joint and therefore the joint did
not fracture on the retreating side but on the advancing side
[8]. The result was still a decay ofmechanical properties, this
situation regards nuggetzone,flowarmzoneandTMAZ[28].
The fracture localization all-occurring at the
HAZ/TMAZ boundary suggested that grain/sub grain

structure, crystallographic texture, and precipitate
overlaying could have contributed to the observedsoftening
at this location [29].
Lee et al studied the friction stir welded A356 alloy
and found that the base metal had a very wide range of
hardness (Figure 6). The hardness of theSZ,incaseof87 and
187 mm/min welding speeds,wasuniformlydistributedand
shows less variation. In contrast, the hardness of the SZ of
267 mm/min welding speed showed a very scattered value.
The average hardness of the SZ slightly decreased with
increasing welding speed [27].
Figure 6. Effect of welding speed on micro-hardness
6. REVIEW SUMMARY
From literature review, it is observed that the friction stir
welding process offersmany advantagesoverfusionwelding
processes for joining Aluminium alloys. However, most of
the reported research papers are focusing on FSW of
wrought Aluminium alloys. Very few papers are found
related to FSW of cast Aluminiumalloys.Thoughthisprocess
shows more promise over fusion welding processes to join
cast Aluminium alloys, the usefulness of this process is not
yet explored by the researchers. Hence, many investigations
have been carried out to make a systematic study to
understand the effect of FSW process parameters on
mechanical and metallurgical properties of cast Al alloys.
REFERENCES
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BIOGRAPHIES
Dr S Boopathi
Associate Processor
Mechanical Engineering
Bannariamman Institute of
technology
Sathyamangalam, Eorde (D.)
638 401
Field Expert: Optimization in
Manufacturing
Mr Kumaresan A
III Year –student
technology
638 401
Mr. Manohar N
III Year –student
technology
638 401
Mr. KrishnaMoorthi R
III Year –student
technology
638 401

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