1

The Solid State Welding

and Processing Techniques

January 2016

Department of

Mechanical Engineering

* ContactsAddress: P.O. Box 14200, FI-00076 Aalto, FinlandVisiting address: Puumiehenkuja 3, Espoopedro.vilaca@aalto.fi ; Skype: fsweldone

Professor Pedro Vilaça *

Materials Joining and NDT

1Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Agenda

Solid state weldingo Classification

o Technological and historical scope

o Joining mechanisms

Overview of Solid State Welding and Processingo Techniques and variants

Friction Stir Weldingo Fundaments

o Industrial applications

o Friction stir welding variants

o Friction stir based processes

2Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

AGENDAOverview of Solid State Welding Processes

High Frequency Welding

Flash Welding

Stud Welding

Cold Pressure Welding

Diffusion Welding

Ultrasonic Welding

Explosion Welding/Cladding and Cutting

Friction Based Technology

3Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

AGENDAOverview of Friction Based Technology

Friction Extrusion

Friction Hydro Pillar

Friction Riveting

Friction Rotary Welding

Friction Linear Welding

Friction Surfacing

Friction Stir Welding

Friction Stir Welding Variants

Friction Stir Based Processes

4Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

AGENDAOverview of Friction Stir Welding Variants

Bobbin-Tool

Static Shoulder

Re-Stir

Dual Rotation

Twin-Stir

Ras-Stir

Skew-Stir

Com-Stir

5Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

AGENDAOverview of Friction Stir Based Processes

Friction Stir Processing

Friction Stir Channelling

Friction Stir Microforming

Friction Stir Embossing

Friction Stir Spot Welding

Friction Spot Welding

Near-Net Shaped

2

6Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technologies

Solid State Welding

Technological Scope

Classification

7Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State WeldingClassification

Welding Process

Classification

Brazing and Soldering No fusion of Base Material components which are

joined by inserting melted Filler Metal in the overlap joint configuration based on capillarity and diffusion

Fusion Welding Includes local fusion of Base Material proceeded by

solidification with/without application of mechanical energy and with/without Filler Metal

Solid State Welding Joining is obtained by solid state joining mechanisms In some processes, superficial melting layer is

produced to then be expelled during forging Flash around weld zone is usual

Note: There are (many) others possible classifications

8Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State WeldingForging Lead the Way

Techniques based on Solid State Welding and Processing are in

permanent advance since many centuries ago resulting

nowadays in some of the most significant progresses in

The Joining Technology (e.g. Friction Stir Welding)

Bear in mind that

“Advanced (Production) Technology”

does include

“Solid State Welding and Processing Techniques”

9Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State WeldingSome Significant Advantages

Reduction of manufacturing costs:

Reduction of energy consumption

(use less and has a higher energy efficiency)

No consumables in most of applications

(e.g. filler material, shielding gases)

Equipment simple and easily automated which do not require

specialized/high skill operators

High productivity, with results easily reproducible

Allow welding materials difficult or impossible to weld by fusion

resulting in joints with excellent mechanical properties (matching BM)

Typically these are all environmentally clean/friend processes

(e.g. without fumes or radiation emission)

In aggressive environments for humans, allow remote operation and

process control

10Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technologies

Solid State Welding

Joining Mechanisms

11Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Joining Mechanisms…Activated During Solid State Welding

Aproximation to Interatomic

Distances of Equilibrium

Diffusion

Clinching

Atomic bonding at joining

materials interfaces

Bonding over an interferential layer

which can reach up to

continuous metallic conditions

Mechanical interference

3

12Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State WeldingEnergetic Activation of Joining Mechanisms

Mechanical

Energy

Heat Energy

Liquid joining interface:High-frequency; Flash; Stud

Welding

Friction; Ultrasonic;Explosion; Diffusion

Welding

Cold Welding

Fusion of a nugget in close die pressured zone:

Resistance Welding

Fusion with no pressure:e.g.: SMAW; GTAW; GMAW; FCAW; SAW ; Laser Welding

Note: Sometimes wrongly classified as

fusion welding!

… these techniques are based on solid state

joining mechanisms!

13Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State WeldingEnergetic Activation of Joining Mechanisms

Expressed as a ternary diagram

In all solid phase welding operations, the controlling parameters are:

1) Time

2) Temperature

3) Deformation

14Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Joining Mechanisms…Activated During Solid State Welding

Mechanical

Energy

Heat Energy

DifusionInterfacial

Atomic bondingInterfacial

Diffusion + Atomic bondingVolumic

w/ visco-plastic material flow

15Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Joining MechanismsGeneration of New Surfaces Chemically Active

Production of New Surfaces by Plastic Deformation:

At room temperature: Highly ductile materials

(typically FCC metallic microstructure)

At high temperature: Most of the engineering materials

Cleaning is Typically Not Enough…

…But is Mandatory and/or Suggested for solid state processes

where no liquidification and/or flash is produced

Original surfaces need to be removed out from final joining interface:

Surface Layer Liquidification + Expelled out

Production of Flash (more or less massive + may or not need to be

removed from weld joint)

Fine Disruption + Dissemination of original superficial particles

within joint

16Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technology

Solid State Welding

Overview of Main Processes

17Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesHigh-Frequency Welding (1/2)

4

18Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesHigh-Frequency Welding (2/2)

Sample of Frequency Ranges:

100kHz - 800kHz

19Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesFlash Welding (1/1)

20Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesStud Welding (1/1)

21Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesCold Pressure Welding (1/3)

22Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesCold Pressure Welding (2/3)

Aluminium - Copper

23Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesCold Pressure Welding (3/3)

Variant: Off-set Flash

5

24Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesDiffusion Welding (1/3)

25Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Autoclave (Oven)

Overview of Solid State ProcessesDiffusion Welding (2/3)

26Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesDiffusion Welding (3/3)

27Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Interfaces in Ultrasonic Welding

Overview of Solid State ProcessesUltrasonic Welding (2/9)

28Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesUltrasonic Welding (3/9)

29Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Question:

What is happening at

contacting interfaces?

Overview of Solid State ProcessesUltrasonic Welding (4/9)

6

30Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Hysteresis Cycle

(elastic domain)

Overview of Solid State ProcessesUltrasonic Welding (5/9)

Sample of Frequency Ranges:

10kHz - 75kHz

31Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

time

Compacting Anchor Welding Excess

Overview of Solid State ProcessesUltrasonic Welding (6/9)

Sequence of stages during the transient cycle of USW

32Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesUltrasonic Welding (8/9)

Old concept equipments

33Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesUltrasonic Welding (9/9)

Application samples in metals

34Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesExplosion Welding (1/5)

35Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesExplosion Welding (2/5)

7

36Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesExplosion Welding (3/5)

37Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesExplosion Welding (4/5)

38Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technology

Friction Based Technology

“Third-Body” Region

39Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

“Third-Body” Region

Based Technology

40Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Based TechnologySample of Processes

Friction Extrusion Friction Hydro Pillar

T

WI, E

ng

lan

d

41Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Riveting at HZG

Courtesy of

8

42Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesFriction Welding (1/13)

Joint design possible solutions

43Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Based TechnologySample of Processes

Friction Welding

Internacional Patent

2/1956 (A.I.Chudikov)

44Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

As welded Tensille test Bending test

Overview of Solid State ProcessesFriction Welding (9/13)

Application samples: Inertia Wheel transmission of CuOFHC / AA4043

45Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesFriction Welding (10/13)

Application samples: Long drilling shafts for in-land prospection

46Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesFriction Welding (11/13)

Inertia wheel transmission application to produce “transmission shafts”

47Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Before...

...After

Overview of Solid State ProcessesFriction Welding (12/13)

Application samples: Manufacture of prostheses

9

48Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of Solid State ProcessesFriction Welding (13/13)

Application samples: Automotive industry

49Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based TechnologyFriction Surfacing: Fundaments

50Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based TechnologyFriction Surfacing: Secondary Flash Formation

Stainless steel rod (AISI 316) over High strength

steel plate (Optim 700 MC Plus)

51Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based TechnologyFriction Surfacing: Secondary Flash Formation

52Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technology

Friction Stir Welding

Fundaments

53Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of FSW FeaturesFSW Licenses Issued by TWI

Cumulative number of licences issued by TWI with time:

10

54Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of FSW FeaturesFundaments and Parameters

Representation of parameters of FSW

55Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Heat Input

56Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Clamping System

Advanced Automatized Solutions

Conventional Solutions

Vacuum

Hydraulic

Magnetic

57Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Joint Design

58Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – (…more) T-Joint Designs

59Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Example of Joints

SPIF of tailored blanks welded by FSW

11

60Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFSW @ Aalto University: Tool Development

Original case study was aluminium fuel tank

• AA5754-H22, 3 mm thick

• Conventional methods versus FSW

After 3 concepts the solution is capable to:

• To produce extruded-like hollow rectangular

structures in AA5XXX series aluminium

• heat input, low distortion, high quality welds

with high strength

• Variable: lenght, width, height and repeatable

Materials Joining and NDTDepartment of Engineering Design

and Production

Friction Stir Welding ProcessApplicability to Engineering Metals

Al Alloys(heat treatable and non heat treatable)

Cu and Cu Alloys

Steel

Mg Alloys

Ti AlloysNi (based) Alloys

62Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of FSW FeaturesBasic Features

Typical transversal macrostructure of a FSW butt joint:

63Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of FSW FeaturesMetallurgical Characterization

AA5083-H111(4.0 mm)

Interface TMAZ/Nugget in transversal macrostructure of a FSW butt joint:

64Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of FSW FeaturesTool Features: Heart of the FSW Process

Retracted-Pin Tool (NASA)

65Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Tool Architecture

Compact tool

Bobbin-toolFixed/Self-adapting Gap

Modular tool

12

66Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Tool Architecture

…for thermoplasticswith/without pre-heat

Stationary Shoulder

Courtesy / Source: TWI

Stationary Shoulder

…for engineering metals

67Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding ProcessFundaments – Tool Architecture

FSW Tool - Assisted by Joule Effect

68Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Overview of FSW FeaturesTools for FSW of HTM: Steel, Titanium, Nickel Based Alloys

Tool Material

(Hybrid WRe:PCBN):

Q60 composite tool consisting of

60% PCBN + 40% W-Re alloy

Shank: tungsten carbide

69Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Modelling of Friction Stir WeldingComplex Multiphysics Coupled Phenomena

Materials Joining and NDTDepartment of Engineering Design

and Production

Friction Stir Welding ProcessFundaments – Advantages versus Disadvantages

Welds materials whose structure and properties would be degraded by fusion welding

Minimal distortion + Low residual stress levels compared to fusion welding processes

Environmentally friendly + Safe: No fumes + No radiation + High energy efficiency

Easy repeatability + Good control: Suitable for automation and robotization

Good mechanical properties: No cracks + No porosity

No consumables (…shielding gas may support the BM and tool for higher temperatures)

Joint can be produced from one side and in all positions

Minimal edge preparation required

Not influenced by magnetic forces

Backing anvil required (except bobbin stir tools)

Keyhole at the end of each weld (except when a tool with a retractable probe is used)

Workpiece requires rigid clamping (except when the Twin-stir™ variant is used)

Application not as flexible as certain fusion welding processes

71Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

FSW Joint Design FeaturesStandards

13

72Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Materials Joining and NDTFSW @ Aalto University

ESAB LEGIOTM

FSW 5UT

Z-axis Control: Position + Speed + Force

Maximum Forces: Fz_max = 100kN (Fx_max = Fy_max = 40kN)

Maximum Welding Travel Speed: Vx_max = Vy_max = 4m/min

Maximum Spindle Power = 30kW ; Maximum Spindle Speed: max = 3000rpm

Work Envelope (x ; y ; z) : 2000mm x 400mm x 300mm

Special focus on the application to: Al, Cu, HSSteels, SSteels, and Ni based alloys

73Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technology

Friction Stir Welding

Industrial Application Samples

74Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

1st know industrial application (~1995) ...

Production of panels from extruded closed profiles for deep-frozen fishing

vessels

Note:

FSW is performed

from both sides of the

butt joint

Industrial ApplicationNaval Industry – Sapa@Sweden

75Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationAeronautic Industry – Eclipse Aviation@USA (1/4)

76Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationAeronautic Industry – Eclipse Aviation@USA (4/4)

Fuselage

77Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Vertical and orbital FSW joints: 1998-

2000

An FSW facility dedicated for the production of the

fuel tanks of Delta IV

Industrial ApplicationAerospace Industry – Boeing Co.@USA (2/4)

14

78Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationAerospace Industry – Boeing Co.@USA (3/4)

New FSW for Space Launch System:

Vertical Assembly Center (VAC)

(NASA’s Michoud Assembly Facility New Orleans)

61 m Tall x 8.4 m Diameter cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s RS-25 engine

79Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationAutomotive Industry

80Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

The special characteristics of the friction stir welded joint enable the forming of the final part

without problem: Ecodal-608 PX sheet (pre-aged T4 temper) .

Dissimilar in Thickness Tailored Blank =1.7 mm + 2.4 mm

Industrial ApplicationAutomotive Industry – AUDI R8 Le Mans (2/2)

81Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationAutomotive Industry

82Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationAutomotive Industry – Sapa, Sweden

A car features

countless

application areas

for aluminium, as

can be seen

in this picture

taken at the

Aluminium 2002

Fair in Germany,

at the SAPA

stand

83Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solution: Replacement of current metals with lighter alloys

Magnesium is a very light alloy (ρ = 1750 kg/m3)

Has a good castability allowing the casting of complex shapes

Challenge

Current joining methods present several difficulties

Critical corrosion susceptibility

FSW is a good method for similar and dissimilar joints with Mg alloys

M.K.Kulekci, “Magnesium and its alloys applications in automotive industry,” Int.J.Adv.Manuf.Technol., 39, 851–865, 2007.

Industrial ApplicationMg Alloy for Automotive Industry

15

84Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Automatized system for FSW of

electric engine housing

Industrial ApplicationHousing – Hydro Aluminium Profile, Norway

85Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationHousing - Bang & Olufsen, Germany

86Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationArchitecture Application – Nobel Peace Centre, Oslo Norway

87Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationSwedish Nuclear Fuel and Waste Management Co (SKB) (1/3)

Final repository for the waste and a

reliable way of encapsulating and sealing

the copper canisters of spent nuclear

fuel, which must remain intact for some

100 000 years. Copper canisters (~ 5 m

long) for spent nuclear waste are

cylindrical, featuring a near 50mm-thick

copper corrosion barrier and a cast iron

insert for mechanical strength. The

canister, with an outer diameter of 105

cm, must be sealed using a welding

method that ensures extremely high joint

quality and integrity.

88Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationShipbuilding Industry – Steel (source: HILDA project)

FSW… Aims to avoid This!

Courtesy / Source: TWI

89Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationApple iMAC 2012 (2/2)

16

90Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationElectrical Transformers Bobbin's - SIEMENS, Portugal (1/2)

91Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Industrial ApplicationElectrical Transformers Bobbin's - SIEMENS, Portugal (2/2)

92Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technology

FSW Based Innovations

FSW Variants

93Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding

Based InnovationsBobbin-Tool Stationary-Shoulder

94Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding

Based InnovationsRas-Stir Skew-Stir Com-Stir

95Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Welding

Based InnovationsRe-Stir Dual-Rotation Twin-Stir

17

96Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Solid State Welding

and Processing Technology

FSW Based Innovations

Friction Stir Based Techniques

97Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Stir Processing

FS Processing apply the principles of FSW to develop materials microstructures and improving superficial and in-volume properties

Cleaning and preparation of surface without special care

Used in different positions with no need of high levels of energy consumed

It is very successful in the modification of various properties such as formability,

hardness, yield strength, fatigue and corrosion resistance

It is also becoming very effective in the production of MMC and for the

production of materials with superplastic behaviour

98Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Stir Processing

Embedding of

SiC particles for FGM

Overlap Ratio OR

Results for:

FS Processing in-Volume

Smooth concave shoulder for better

superficial appearance

99Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Stir Channelling

FSC is an innovative process within solid-phase manufacturing technologies able to produce, in a single operation, continuous internal (closed) channels in monolithic plates

FSC is a disruptive innovation enabling higher efficiency in energetic applications and advances of structural design of products

Channels can have any path and many different shapes and locations

100Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Stir Channelling: Potential Applications

Conformal Cooling of Mould Cavity

101Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Stir Microforming

Friction stir microforming (FSM) is an integration of friction stir technology

with superplastic materials science, to microform metallic parts

Friction stir microforming of superplastic aluminum alloys Al-7075 and Al-4Mg-1Zr [Mishra]

Microdie used for forming the microparts consists of two rectangular 1mm long microEDM

channels, 100 and 200 mm wide, and 500 mm in depth

Applications:

• Micro-electromechanical systems (MEMS) + Microsystem technologies (MST)

18

102Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsSelf Embossing and In-Process Forge/Forming

Impressed marks can be produced during the FSW operation and came

from inverse engraving in the anvil support plate

Self embossing - showing impressed marks produced during

the FSW operation [Courtesy of TWI]

Embossed FSW weldEngraved anvil

103Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Stir Spot Welding

104Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsFriction Spot Welding

105Engineering Materials

Materials Joining and NDTDepartment of Mechanical Engineering

Friction Stir Based InnovationsNear-Net Shaped Manufacture

6 mm X 6 mm thick AA5083