Nowadays, the friction stir welding and friction stir spot welding are developing rapidly, so that can we see this type of friction replace normal types of welding?
Hi Raheem,
It is an interesting question. Can this process replace the other dated fusion welding processes?
In my point of view, friction stir welding (FSW) and friction stir spot welding (FSSW) have a lot of potential in producing components with enhanced mechanical properties specifically in the welded zone by employing some novel techniques. However. I think there are several restrictions using these approaches. A short list of disadvantage can be as follows:
1- In contrast to the conventional approaches where the susceptible areas to failure are the fusion zone (FZ) and heat affected zone (HAZ), in FSW the thermomechanical affected zone (TMAH) is also can be considered as a source of failure in some circumstances. Therefore, extra heat treatment cycles may be needed to overcome this barrier.
2- Components with complex geometries can not be welded using FSW. However, I believe FSSW has solved this problem. On the contrary, many of the complex components are being welded and manufactured by conventional techniques much easier.
3- In industrial production scale, using a cost effective method is the number one priority. where these FSW and FSSW techniques require high-cost machinery maintenance, producing specific types of pin and etc. where the list can go on.
4- FSW and FSSW machinery can be much expensive that the conventional techniques.
In recent years, many researchers have focused their efforts on modification and enhancement of these processes and I think these techniques show potential to be used for strategic purposes; such as modifying mechanical properties in the weld zone, reducing inclusion during welding and etc..
In brief, the existence of some financial and technological barriers can limit the use of FSW and FSSW.
Best,
Farhad
Dear Farhad
Thank you very much for your reply.
Yes, I think "the existence of some financial and technological barriers can limit the use of FSW and FSSW." But do you think think the rapid development of this type of welding can be lead to overcome these difficult in near future.
Nowadays, the stir welding become as separate branch of the welding and many specific conferences taken place from time to time such as 5th INTERNATIONAL CONFERENCE ON SCIENTIFIC AND TECHNICAL ADVANCES ON FRICTION STIR WELDING & PROCESSING which will be in France during next October.
Best regards
Dear Raheem,
That's interesting, I didn't know that there is a separate conference holding for FSW technique. In addition to your comment, FSW and FSSW can be categorized as the solid state welding, in my viewpoint. There are several solid state welding techniques that are being in the interest of other researchers, including:
1- Cold Welding,
2- Diffusion Welding,
3- Forge Welding,
4- Friction Welding; which is the topic of this question,
5- Ultrasonic Welding and
6- etc.
I think friction welding can be used in various industries since the welding time and input energy is not that much that the other solid state techniques require. Despite those restrictions that I and you have mentioned previously, I think these techniques can be the next promising generation of welding methods. However, I think the main challenge would be the science part of the process, I mean the material science. It's very important to produce a component with improved mechanical and physical properties; even modified texture in some cases. So, this is going to be interesting.
Best,
Farhad
The welding speed is too low compared to fusion welding. On the other hand, the tool cost is too much for welding steel, titanium or nickel alloys. Hence, FSW may not cause extinction of fusion welding. However, FSW will be applied to specific precise components where higher strength and fine microstructure are required. Further, FSW will be extensively used for dissimilar joints which are difficult to achieve by fusion welding.
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