Project Report Final

Team ID: 44124 Friction Stir Welding (2015-2016)
“PARAMETRIC OPTIMIZATION OF FRICTION STIR

WELDING USING DIFFERENT TOOL PROFILES”
By
Ahuja Rakesh N. (120800119002)
Lathigra Chirag M. (120800119003)
Patel Purvesh D. (120800119011)
Under the guidance of

Vimal B. Patel
Assistant Professor,
Mechanical Engineering Department,
VIER, Kotambi.
A Project Report Submitted to

Gujarat Technological University
In Fulfillment of the requirements for
The Degree of Bachelor of Engineering in Mechanical Engineering.
2015 - 2016
Department Of Mechanical Engineering

Vadodara Institute Of Engineering, Kotambi.
Vadodara Institute of Engineering, Kotambi. Page i

CERTIFICATE
This is to certify that the research work embodied in this thesis entitled “PARAMETRIC
OPTIMIZATION OF FRICTION STIR WELDING USING DIFFERENT TOOL PROFILES” was
presented by Ahuja Rakesh N. (120800119002), Lathigra Chirag M. (120800119003),
Patel Purvesh D. (120800119011) at VADODARA INSTITUTE OF ENGINEERING, KOTAMBI
for partial fulfillment of B.E. in Mechanical Engineering to be awarded by Gujarat
Technological University. This work has been carried out under my supervision and is to the
satisfaction of department.
Date:
Place:
Guide: H.O.D:
Mr. Vimal B Patel Mr.Vishvas B Rajyaguru
Assistant Professor, Head of department
VIER, Kotambi. VIER, Kotambi.
Seal of Institute
Vadodara Institute of Engineering, Kotambi. Page ii

DECLARATION OF ORIGINALITY
I hereby certify that I am the sole author of this thesis and that neither any part of this thesis
nor the whole of the thesis has been submitted for a degree to any other University or
Institution.
I Certify that, to the best of my knowledge, my thesis does not infringe upon anyone’s
copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any
other material from the work of other people included in my thesis, published or otherwise,
are fully acknowledged in accordance with the standard referencing practices. Furthermore,
to the extent that I have included copyrighted material that surpasses the bounds of fair
dealing within the meaning of the Indian Copyright Act.
I declare that this is a true copy of my thesis, including any final revisions, as approved by
my thesis review committee.
Date:
Place:
Signature of Students: Signature of Guide:

Name of Students: Name of Guide:
Ahuja Rakesh N. (120800119002) Vimal B. Patel
Lathigra Chirag M. (120800119003) Institute code: 080
Vadodara Institute of Engineering, Kotambi. Page iii

APPROVAL CERTIFICATE
This is to certify that research work embodied in this thesis entitled “PARAMETRIC
OPTIMIZATION OF FRICTION STIR WELDING USING DIFFERENT TOOL
PROFILES” was carried out by Ahuja Rakesh N. (120800119002), Lathigra Chirag M.
(120800119003), Patel Purvesh D. (120800119011) at VADODARA INSTITUTE OF
ENGINEERING, KOTAMBI is approved for award of the degree of “BACHELOR OF
ENGINEERING IN MECHANICAL ENGINEERING” by Gujarat Technological
University.
Date:
Place:
Examiner(s):
________________ ________________ ________________
( ) ( ) ( )
Vadodara Institute of Engineering, Kotambi. Page iv

ACKNOWLEDGEMENT
It has been a great honour to work, right from the conceptualization of the topic to
completion of the entire work of the dissertation, under the guidance of my honourable and
respected guide, Mr. Vimal B. Patel, Associate Professor in Mechanical Engineering
Department (VIER, Kotambi). I sincerely acknowledge them valuable contribution. They are
a constant source of encouragement and momentum that any difficulty becomes simple. They
always supported and tolerated me (including my silly mistakes and lethargy). I gained a lot
of valuable guidance and prompt suggestions from them during the entire work schedule.
It gives me pleasure to express my deep sense of gratitude to Mr. Vishhvas B. Rajyaguru

Professor and Head of the Mechanical Engineering Department and Dr. J. S. Patel Principal
to provide great opportunity to carry out this dissertation work as a part of the curriculum.
I am also thankful to all the faculty members of Mechanical Department as they spent their
valuable time in guiding me in my dissertation work.
Thank You …by

Ahuja Rakesh N. (120800119002)
Lathigra Chirag M. (120800119003)
Vadodara Institute of Engineering, Kotambi. Page v

ABSTRACT
Amongst the emerging new welding technologies, friction stir welding (FSW), invented and
established by The Welding Institute (TWI) in 1991, is used frequently for welding of high
strength aluminium alloys such as AA6061, AA6082, etc. which are difficult to weld by
conventional fusion welding techniques. Friction welding (FW) is a collection of a series of
friction-based solid state joining processes which can produce high quality welds of different
components with either similar or dissimilar materials and has been attracting increasing
attention. The project aim is to weld two plates of AA 6082 using different tool profiles and
to optimize the parameters like tool rotational speed, tool profile, depth of cut, feed etc.
affecting the properties of welded joints.
Vadodara Institute of Engineering, Kotambi. Page vi

Index
 CERTIFICATE II
 DECLARATION OF ORIGINALITY III
 APPROVAL OF CERTIFICATE IV
 ACKNOWLEDGEMENT V
 ABSTRACT VI
1. Introduction
1.1 introduction to welding 8
1.2 welding processes 8
1.3 friction stir welding 11
1.4 problem statement 16
2. Literature survey
2.1 review of technical research papers 17
2.2 patent search 22
3. Canvas 25
4. Methodology and setup

4.1 objectives 28
4.2 material selections 28
4.3 tool profile 31
4.4 input parameters 32
4.5 testing methods 35
5. Implementation and experimental work

5.1 friction stir welding on VMC machine. 37
5.2 testing of Joints and Results 39
6. Conclusion and future scope 50
7. References 51
Vadodara Institute of Engineering, Kotambi. Page 7

Chapter 1: Introduction
1.1 Introduction to welding
Welding is the process of metal joining with help of heat, with or without pressure.
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics,
by causing fusion, which is distinct from lower temperature metal-joining techniques such
as brazing and soldering, which do not melt the base metal. In addition to melting the base
metal, a filler material is often added to the joint to form a pool of molten material (the weld
pool) that cools to form a joint that can be as strong as the base material. Pressure may also
be used in conjunction with heat, or by itself, to produce a weld.
Many different energy sources can be used for welding, including a gas flame, an electric arc,
a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding
may be performed in many different environments, including in open air, under water, and
in outer space. Welding is a hazardous undertaking and precautions are required to
avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and
exposure to intense ultraviolet radiation.
In this report we will come across classification of different welding procedure and
their uses and we will mainly focus on FRICTION STIR WELDING which is one of the
types of friction welding. [1]
1.2 Welding Processes
1.2.1 Arc welding
These processes use a welding power supply to create and maintain an electric arc
between an electrode and the base material to melt metals at the welding point. They can use
either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.
The welding region is sometimes protected by some type of inert or semi-inert gas, known as
a shielding gas, and filler material is sometimes used as well.
There are different types of Arc welding.
1. Shielded metal arc welding (SMAW) - also known as "stick welding or electric welding",
uses an electrode that has flux, the protecting for the puddle, around it. The electrode holder
holds the electrode as it slowly melts away. Slag protects the weld puddle from atmospheric
contamination.

2. Gas tungsten arc welding (GTAW) - also known as TIG (tungsten, inert gas), uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from
atmospheric contamination by an inert shielding gas such as Argon or Helium.
3. Gas metal arc welding (GMAW) - commonly termed MIG (metal, inert gas), uses a wire
feeding gun that feeds wire at an adjustable speed and flows an argon-based shielding gas or
a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from atmospheric
contamination.
4. Flux-cored arc welding (FCAW) - almost identical to MIG welding except it uses a
special tubular wire filled with flux; it can be used with or without shielding gas, depending
on the filler.
5. Submerged arc welding (SAW) - uses an automatically fed consumable electrode and a
blanket of granular fusible flux. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under the flux blanket.
1.2.2 Oxyfuel gas welding
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas

welding in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen
to weld and cut metals, respectively. French engineers Edmond Fouché and Charles Picard
became the first to develop oxygen-acetylene welding in 1903. Pure oxygen, instead of air, is
used to increase the flame temperature to allow localized melting of the work piece material
(e.g. steel) in a room environment. A common propane/air flame burns at about 2,250 K
(1,980 °C; 3,590 °F), a propane/oxygen flame burns at about 2,526 K (2,253 °C;
4,087 °F), and an acetylene/oxygen flame burns at about 3,773 K (3,500 °C; 6,332 °F).[19]
1.2.3 Resistance welding

Electric resistance welding refers to a group of welding processes such as spot and
seam welding that produce coalescence of faying surfaces where heat to form the weld is
generated by the electrical resistance of material combined with the time and the force used
to hold the materials together during welding.
There are three types of Resistance welding:
1. Spot welding-Spot welding is a resistance welding method used to join two or more
overlapping metal sheets, studs, projections, electrical wiring hangers, some heat exchanger

fins, and some tubing. Usually power sources and welding equipment are sized to the specific
thickness and material being welded together. The thickness is limited by the output of the
welding power source and thus the equipment range due to the current required for each
application.
2. Seam welding-Resistance seam welding is a process that produces a weld at the faying
surfaces of two similar metals. The seam may be a butt joint or an overlap joint and is usually
an automated process. Seam welding relies on two electrodes, usually made from copper, to
apply pressure and current. The electrodes are disc shaped and rotate as the material passes
between them. This allows the electrodes to stay in constant contact with the material to make
long continuous welds. The electrodes may also move or assist the movement of the material.
3. Low frequency electric resistance welding-Low-frequency electric resistance

welding, LF-ERW, is an obsolete method of welding seams in oil and gas pipelines. It was
phased out in the 1970s but as of 2015 some pipelines built with this method remained in
service. [19]
1.2.4 Solid state welding:

Solid state welding is a group of welding processes which produces coalescence at
temperatures essentially below the melting point of the base materials being joined, without
the addition of brazing filler metal.
There are different types of solid state welding.
1. Cold welding-Cold welding is a solid state welding process which uses pressure at room
temperature to produce coalescence of metals with substantial deformation at the weld.
2. Diffusion welding-Diffusion welding is a solid state welding process which produces

coalescence of the faying surfaces by the application of pressure and elevated temperatures.
The process does not involve microscopic deformation melting or relative motion of the
parts. Filler metal may or may not be used. This may be in the form of electroplated surfaces.
3. Explosion welding- Explosion welding is a solid state welding process in which

coalescence is effected by high-velocity movement together of the parts to be joined
produced by a controlled detonation. Even though heat is not applied in making an explosion
weld it appears that the metal at the interface is molten during welding.
4. Forge welding-Forge welding is a solid state welding process which produces coalescence
of metals by heating them in a forge and by applying pressure or blows sufficient to cause
permanent deformation at the interface. This is one of the older welding processes and at one
time was called hammer welding. Forge welds made by blacksmiths were made by heating
the parts to be joined to a red heat considerably below the molten temperature.
5. Friction welding- Friction welding is a solid state welding process which produces
coalescence of materials by the heat obtained from mechanically-induced sliding motion
between rubbing surfaces. The work parts are held together under pressure. This process
usually involves the rotating of one part against another to generate frictional heat at the
junction.
6. Hot pressure welding-Hot pressure welding is a solid state welding process which
produces coalescence of materials with heat and the application of pressure sufficient to
produce macro-deformation of the base metal.
7. Roll welding- Roll welding is a solid state welding process which produces coalescence of
metals by heating and by applying pressure with rolls sufficient to cause deformation at the
faying surfaces. This process is similar to forge welding except that pressure is applied by
means of rolls rather than by means of hammer blows. Coalescence occurs at the interface
between the two parts by means of diffusion at the faying surfaces.
8. Ultrasonic welding- Ultrasonic welding is a solid state welding process which produces
coalescence by the local application of high-frequency vibratory energy as the work parts are
held together under pressure. Welding occurs when the ultrasonic tip or electrode, the energy
coupling device, is clamped against the work pieces and is made to oscillate in a plane
parallel to the weld interface. [19]
1.3 Friction Stir Welding

Friction-stir welding (FSW) is a solid-state joining process (the metal is not melted) that
uses a third body tool to join two facing surfaces. Heat is generated between the tool and
material which leads to a very soft region near the FSW tool. It then mechanically intermixes
the two pieces of metal at the place of the joint, then the softened metal (due to the elevated
temperature) can be joined using mechanical pressure (which is applied by the tool), much
like joining clay, or dough. It is primarily used on aluminium, and most often on extruded
aluminium (non-heat treatable alloys), and on structures which need superior weld strength
without a post weld heat treatment.
It was invented and experimentally proven at The Welding Institute UK in December 1991.
TWI holds patents on the process, the first being the most descriptive. [1]

[fig.: friction stir welding process]
1.3.1 Working Principle

A constantly rotated non consumable cylindrical-shouldered tool with a profiled
probe is transversely fed at a constant rate into a butt joint between two clamped
pieces of butted material.
The probe is slightly shorter than the weld depth required, with the tool shoulder
riding atop the work surface. Frictional heat is generated between the wear-
resistant welding components and the work pieces.
This heat, along with that generated by the mechanical mixing process and
the adiabatic heat within the material, cause the stirred materials to soften
without melting. As the pin is moved forward, a special profile on its leading face
forces plasticised material to the rear where clamping force assists in a forged
consolidation of the weld.
This process of the tool traversing along the weld line in a plasticised tubular shaft
of metal results in severe solid state deformation involving dynamic re-crystallization
of the base material.[2]

1.3.2 Process Parameter
1. Tool design-The design of the tool is a critical factor as a good tool can improve
both the quality of the weld and the maximum possible welding speed. It is desirable
that the tool material is sufficiently strong, tough and hard wearing, at the welding
temperature.
2. Tool rotational speed-Friction stir welding is a solid state joining process, in this
process welding is done by producing friction between tool pin profile and plate. The
generation of friction between them is depend on Rotational speed. When rotational
speed of the tool is increase or decrease weld quality is increase or decrease
respectively
3. Welding feed speed- With increase in welding feed speed the temperature decrease
at local position. With slow welding feed speed the temperature will increase.
4. Axial force- If the thickness of the material increases the required axial force for
welding also increases. [4]

1.3.3 Application
1. Shipbuilding and Marine Industries:

The shipbuilding and marine industries are two of the first industry sectors which
have adopted the process for commercial applications. The process is suitable for the
following applications:
 Panels for decks, sides, bulkheads and floors

 Aluminium extrusions
 Hulls and superstructures
 Marine and transport structures
 Masts and booms, e.g. for sailing boats
2. Aerospace Industry:
At present the aerospace industry is welding prototype and production parts by
friction stir welding. Opportunities exist to weld skins to spars, ribs, and stringers for use in
military and civilian aircraft. Longitudinal butt welds in Al alloy fuel tanks for space
vehicles have been friction stir welded and successfully used. The friction stir welding
process can therefore be considered for:
 Wings, fuselages, empennages.
 Cryogenic fuel tanks for space vehicles.
 Aviation fuel tanks.
 Military and scientific rockets.
 Various primary and secondary structural components.
3. Railway Industry: The commercial production of high speed trains made from
aluminium extrusions which may be joined by friction stir welding has been published.
Applications include:
 High speed trains.

 Rolling stock of railways, underground carriages, trams.
 Railway tankers and goods wagons.
 Container bodies.
4. Other Industry Sectors:
Friction stir welding can also be considered for:
 Electric motor housings (in production),

 Refrigeration panels,
 Cooking equipment and kitchens,
 Gas tanks and gas cylinders,
 Connecting of aluminium or copper coils in rolling mills.[19]

1.3.4 Advantages
1. Low heat distortion.

2. Improved mechanical properties.
3. No fumes.
4. No consumables — a threaded pin made of conventional tool steel, e.g., hardened H13,
can weld over 1 km (0.62 mi) of aluminium, and no filler or gas shield is required for
aluminium.
5. Easily automated on simple milling machines — lower setup costs and less training.
6. Can operate in all positions (horizontal, vertical, etc.), as there is no weld pool.
7. Generally good weld appearance and minimal thickness under/over-matching, thus

reducing the need for expensive machining after welding.
8. Low environmental impact.
9. Excellent repeatability.
10. Low tool cost.
11. No consumables. [19]
1.3.5 Limitation
1. Exit hole left when tool is withdrawn.
2. Large down forces required with heavy-duty clamping necessary to hold the plates
together.
3. Less flexible than manual and arc processes (difficulties with thickness variations and non-
linear welds).
4. Often slower traverse rate than some fusion welding techniques, although this may be
offset if fewer welding passes are require
5. High investment
6. Extensive clamping.
8. Need backing support
9. Critical tolerances. [19]

1.4 Problem Statement
 In Friction stir welding the design of tool is very crucial task because it directly
affects the strength of the joint.
 The process parameters like tool speed, feed and depth of cut should be selected such
that which provides max strength at minimum machine load.
 In this process with increase in material thickness to be weld the axial load required
from machine also increases so it has certain limit to weld very thick materials.
 The material range compatible for friction stir welding is also small.
 The machine set up time with generation of program is time consuming process.

Chapter-2 Literature survey
2.1 Review of Technical Research Papers
PAPER 1
TITLE: -An Overview of Friction Stir welding (May-Oct. 2013)
AUTHOR: suresh babu, C. devnathan
SUMMARY: In the past two decades friction stir welding has been evolved as a successful
welding technique for joining all hard materials and metal matrix composites in addition to
aluminium. This is possible because, joining is established by means grain refinement which
will also lead to increase in mechanical properties. During joining, the number of parameters
required to control is limited and which can be easily controlled to produce the sound weld.
Machine controllable parameters are having direct proportional relation with mechanical
properties except welding speed. FSP and FSSW are the two variants in friction stir welding.
Former can become a successful method to produce surface composites, super plastic
forming, later can be a good alternate method to resistance spot welding. Friction stir welding
joints are prone to different types of defects which we can eliminate by choosing the proper
tool design and process parameters. This process is less tried to weld hard materials due to
the Lack of tool material and tool design. Tool wear will be the major problem while welding
the metal matrix composites due to the presence of hard ceramic particles. More work has to
be done in online monitoring of the process, online defect detection, controlling the
temperature during the process. [2]
PAPER 2
TITLE: -Effect of various process parameters on friction stir welded joints (Jan-Feb. 2011)
AUTHOR: shrikant G. Dalu, M. T. Shete
SUMMARY: This paper is a review of research work in the last decade on friction stir
welding. Research is going on to investigate the effect of various process parameters on
quality of the welded joint. In this study, the investigation is made on the effect of various
process parameters, such as tool rotational speed, traverse speed, axial force and tool
geometry on the quality of the welded joint are reviewed. Yield strength, ultimate strength,
elongation, toughness, microstructure of the joint are evaluated and correlated with received
base material. To compare and validate experimental results, FEA model is the best way to
study the quality of welded joint. Tool rotation speed, traverse speed, axial force and tool
design are the most significant process parameters in friction stir welding. This paper is a
review of research work in the last decade on friction stir welding. Research is going on to
investigate the effect of various process parameters on quality of the welded joint. In this

study, the investigation is made on the effect of various process parameters, such as tool
rotational speed, traverse speed, axial force and tool geometry on the quality of the welded
joint are reviewed. Yield strength, ultimate strength, elongation, toughness, microstructure of
the joint are evaluated and correlated with received base material. To compare and validate
experimental results, FEA model is the best way to study the quality of welded joint. [12]
PAPER 3
TITLE: Influence of process and tool parameters on friction stir welding. (July-September
2014)
AUTHOR: Aleem pasha m.d., ravinderreddy, laxminarayana, ishtiaqahmad khan.
SUMMARY: In friction stir welding Cost effective and long life tools are available for the
FSW of aluminium and other soft alloys. They are needed but not currently available for the
commercial application of FSW to high strength materials. Tool material properties such as
strength, fracture toughness, hardness, thermal conductivity and thermal expansion
coefficient affect the weld quality, tool wear and performance. Reactivity of tool material
with oxygen from the atmosphere and with the work piece is also an important consideration.
Further developments in FSW tool materials are required to address the problem of high tool
cost with low tool life during welding of harder alloys. Heat generation rate and plastic flow
in the work piece are affected by the shape and size of the tool shoulder and pin. Although
the tool design affects weld proper-ties, defects and the forces on the tool, they are currently
designed empirically by trial and error. Work on the systematic design of tools using
scientific principles is just beginning. Examples of recent studies include calculation of flow
fields for different tool geometries and the calculation of tool shoulder dimensions based on
the tool’s grip of the plasticised material. The pin cross-sectional geometry and surface
features such as threads influence the heat generation rates, axial forces on the tool and
material flow. Tool wear, deformation and failure are also much more prominent in the tool
pin compared with the tool shoulder. The axial, longitudinal and lateral forces on the tool can
be calculated as functions of process parameters, or evaluated from the measure data.
Estimation of the load bearing ability of the tool pin is needed considering the maximum
stresses in the tool pin due to combined effects of bending and torsion. There is a need for
concerted research efforts towards development of cost effective durable tools for
commercial application of FSW to hard engineering alloys. [4]
PAPER 4
TITLE: Simulation of flow stress, temperature and pressure on friction stir welding of edge
joint on similar aluminium alloys 6061(May-June 2014)
AUTHOR: Akshay H Pansuriya ,Jaimin B Patel ,Hitesh Prajapati
SUMMARY: Friction stir welding process is used for joining material such as Aluminium,
copper, magnesium etc., which are otherwise difficult to weld by the conventional welding
processes .The tool pin profile plays a critical role in determining the end properties of the
welding joint apart from other parameter like rotation speed, traverse speed, welding speed,
and axial load. The purpose of the investigations was to elaborate a set of FSW parameters
for connecting 6061 aluminium alloy sheets allowing to produce welds of highest strength.
The results of present experiments are adding new information on FSW of the aluminium
alloys, especially 6061 type. The applied welding parameters provide good quality of welds.
The aim behind. In analysis we use AA6061 similar material for flow stress, temperature and
pressure analysis with Hyper works 9.0. [11]
PAPER 5
TITLE: Comparison of heavy alloy tool in friction stir welding (Jan-Feb.2012)
AUTHOR: Dr.T.Parameshwaran Pillai, S.K.Selvam
SUMMARY: Friction stir welding is the renowned technology widely used for joining
materials. It avoids many of the common problems that persist in fusion welding. It is most
suitable for joining soft materials like Aluminium and Magnesium alloys. Though this
technology has been proven commercially feasible for soft materials, the same for harder
alloys is yet to be established. The development of cost effective and durable tools, which
lead to structurally sound welds, is still awaited. Material selection and design intensely
affect the performance the tools.. Investigation effort has been made for newer compositions
of heavy alloy tool manufactured through powder metallurgy route. Establishing welding
parameters such as tool rotations speed, traverse speed and various mechanical properties of
Heavy alloy tool by numerical analysis and computational fluid dynamics model predicted
values from it. Heavy alloy tool is suitable for cost effective and durable tool in hard alloys
such as stainless steel. [10]
PAPER 6
TITLE: Finite Element Simulation of Friction Stir Butt Welding of AA4047 Aluminium
Plates (Sep.-Oct.2011)
AUTHOR: Samir K. Panda, Polymer Chandrasekhar & Dr. Saranjit Singh.
SUMMARY: The present paper focus on the finite element simulation of the friction stir
welding (FSW) of AA4047 Aluminium plates based on the commercial numerical
codes of Altair Hyper works with an objective to investigate the complex interaction
of thermo-mechanical process characteristics of FSW. A 3D finite element model
(FEM) heat transfer model has been proposed and temperature and pressure
distribution along with the variation of flow stress during the welding of plates was
critically investigated. Also, Taguchi L9 orthogonal array technique was used to
optimize the process parameters for obtaining defect-free high-quality welds. It is

expected that the present work will be useful for understanding the underlying
physics and thermo-mechanical mechanism of FSW. [5]
PAPER 7
TITLE: A STUDY OF PROCESS PARAMETERS OF FRICTION STIR WELDED AA-
6061 ALUMINUM ALLOY (june-2013).
AUTHOR: Prashant Prakash, Sanjay Kumar Jha, Shree Prakash Lal.
SUMMARY: It can be concluded that by varying the process parameters within the range:
Case I: Tool rotation speed 1120 rpm, Welding speed 20 mm/min and Pin
length of the tool 5.2mm.Tensile strength obtained is 142Mpa. Case II: Tool
rotation speed 1400 rpm, Welding speed 25 mm/min and Pin length of the
tool 5.7mm. Tensile strength obtained is 182Mpa. From the two cases it has
been observed that the maximum tensile strength obtained is 182 Mpa from
case II. We know that tensile strength of base material is 320Mpa; it means
the joint efficiency is 60%. [8]
PAPER 8
TITLE: The Effect of Rotational Speed on Flow Behaviour and Weld Properties in Friction
Stir Welding of Pure Aluminium (30 July 2013).
AUTHOR: Hasan I. Dawood , Kahtan S. Mohammed and Zurida A. Wahab.
SUMMARY: The problems of weld defects like voids, cracks, distortion are still
representing a serious headache to the researchers in the welding community.
This article is a preliminary study to adapt the tools, machine parameters and
the work piece. It aims to examine the effect of probe rotational speed on the
mechanical and microstructural properties of the weld joints. In fact this
research is a part of a comprehensive research comprises the effect of probe
profile, shape, pin length, traverse speed, preheating, tilt angle, applied load
and heat transfer parameters on FSW of Al alloys. Advanced Four different
regions were distinguished in Al-Al FSW process, the NZ, TMAZ, HAZ and
the BM. Controlling the welding parameters particularly the rotation speed
and the probe design has yield sound and defect free weldments. The NZ
showed lower hardness value as opposed to that of the base metal indicating
multiple contradiction effects of work hardening, softening and grain
refinement acting simultaneously. However, at rotational speed of 1500 rpm
the weld joint showed no sign of surface defect such as porosities, cracks and
inclusions. The outcome was weld joints of strength higher than that of the
base metal. [9]

PAPER 9
TITLE: Friction Stir Welding – Process and its Variables: A Review (12 December 2012)
AUTHOR: Mandeep Singh Sidhu, Sukhpal Singh Chatha
SUMMARY: 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. Initially, the process was regarded as a “laboratory”
curiosity, but it soon became clear that FSW offers numerous benefits in the
fabrication of aluminium products. Friction Stir Welding (FSW) has become
a major joining process in the aerospace, railway and ship building industries
especially in the fabrication of aluminium alloys. The process uses a spinning
non-consumable tool to generate frictional heat in the work piece.
Worldwide, there are now over 135 licensees of FSW and new techniques
and applications are being developed daily. This paper looks at the review, on
friction stir welding process, various welding variables like tool rotation,
transverse speed, tool tilt, plunge depth and tool design, for the welding of
aluminium alloys or various dissimilar alloys. Applications, future aspects
and several key problems are also described. [6]
PAPER 10
TITLE: Review Paper on Friction Stir Welding of various Aluminium Alloys (23 May 2014)
AUTHOR: Sivakumar, Vignesh Bose, D.Raguraman, D. Muruganandam
SUMMARY: The present review has demonstrated the extensive research effort that
continues to progress the understanding of FSW of aluminium alloys and its
influence on their microstructure and properties. It identifies a number of
areas that are worthwhile for further study. From an engineering perspective,
there is a need to investigate the occurrence and significance of flaws in
friction stir welds. In particular, the influence of tool design on flaw
occurrence and the development of non-destructive testing techniques to
identify flaws in both lap and butt welds would be beneficial. Metal flow
modelling may have a role to play here, though capturing this aspect of the
thermo mechanical behaviour remains a significant challenge. [3]

2.2 Patent search activity
PATENT 1
TITLE: Friction stir welding apparatus (12 march2009)

INVENTORS: James t. Burg, Israel Stol, Donald j. Spinella, John w. Cobes.
PATENT NUMBER: US2009/0065553 A1
SUMMARY: the portable friction stir welding machine disclosed herein can be configured
as a crawler having a top member which supports a motor, such as a torque motor, having a
rotary shaft for rotating a friction stir welding tool and a drive mechanism for pulling a
crawler along a predefined weld path of work pieces. The crawler can comprise one member
or a set of two or three physically separated members each rotatable coupled to the friction
stir welding tool. When one member is used to make a weld, it is located on top of the work
pieces. When two members are used to make a weld, one member is located on the top of the
work pieces and the second member is located on bottom of the work pieces. When three
members are used to make two welds simultaneously on an upper work piece and a lower
work pieces, one member of the crawler is located on the top surface of the upper work piece,
a second member is located between the two work pieces, and the third member is located on
the bottom surface of the work piece.
PATENT 2
TITLE: Friction welded fastener process (8 may 2001)
INVENTORS: Douglas j. Waldron, Robert Scott forest, Ray F. Toosky.
PATENT NUMBER: US 6,227,433 B1
SUMMARY: A process for joining two or more overlapping metal work pieces includes
providing a fastener which is made of metal having a melting point temperature at least as
great as that of the work pieces. The fastener is rotated about its central axis and is axially
advanced at a predetermined advance rate into engagement with the work pieces so as to
cause plasticization of the work pieces at the interface with the fastener, and to cause the
fastener to axially penetrate through substantially the entire thickness of the work pieces. The
present invention overcomes the drawbacks of conventional mechanical fastening processes
noted above, by providing a process for friction welding a fastener through two or more work
pieces so that a metallurgical bond is formed between the work pieces and the fastener. No
holes need be formed through the work pieces prior to application of the fastener, thus
reducing manufacturing cost and eliminating stress concentrations associated with holes and
their attendant disadvantages noted above. Furthermore, the fastener does not require any
head portions, thereby reducing weight. Additionally, no sealants are required because the

metallurgical bond with the fastener provides sealing and protection against corrosion, further
reducing manufacturing cost.
PATENT 3
TITLE: Friction stir welding tool (25 April 2000)
INVENTORS: robert james heideman, Jason winton thomas Scott, Christopher brian smith,
Thomas Michael thessin, brahmanpalli.
PATENT NUMBER: 6,053,391
SUMMARY: A stir weld tool of the present invention is used to weld two pieces of metal
together through frictional heating, plasticizing, mixing, and forging of the plasticized metal
into a uniform element. The stir weld is accomplished by rotating the stir weld tool with a pin
having at least one boss on its surface to create the mechanical friction in the metal in contact
with the rapidly rotating pin. As the rotating pin travels along the weld joint, the plasticized
metal of the work pieces is extruded to the back face of the pin while undergoing a
mechanical stirring and forging from action imparted by the at least one boss on the surface
of the pin, and while confined from above by the pressure exerted on the metal by a shoulder
on the stir weld tool. Other objects of the present invention and many of the attendant
advantages of the present invention will be readily appreciated as the same become better
understood by reference to the following detailed description when considered in connection
with the accompanying drawings.
PATENT 4
TITLE: Advanced friction stir welding tools (02 March 2006)
INVENTORS: Stol, Israel, Cobes, John W.
PATENT NUMBER: US20060043151
SUMMARY: A friction stir welding tool includes an integral shank-pin unit and a shoulder
attached to the shank-pin unit. In one aspect, the present invention teaches an FSW tool
wherein the pin and shank are integrally (monolithically) formed so as to be precisely
concentric. A shoulder is attached to the shank-pin unit. In another aspect, the present
invention teaches an FSW tool having an axial tension member to reduce the damaging
effects of cyclic bending moment loading on the pin as it is moved along a joint being
welded. This type of loading gets compounded by simultaneously inducing bending-shear,
bending-tensile and torsional-shear stresses at various portions of the pin. In an additional
aspect, the present invention teaches an FSW tool having cooling ducts for a coolant fluid to
lower its temperature.

PATENT 5
TITLE: Friction stir welding method (20 April 2004)
INVENTORS: Ezumi, Masakuni, Fukuyori, Kazushige, Mizusaki, Tsuyoshi
PATENT NUMBER: 6722555

SUMMARY: An object of the present invention is provide to a friction stir welding method
in which welding along a path having a ring shape or a circular shape (a circular arc is
included) during the friction stir welding can be carried out easily. The above-stated object
can be attained by a friction stir welding method, characterized in that a first member and a
second member are fixed on a table of a machine tool having a main shaft onto which a rotary
tool is installed; and then, the table is rotated relative to an axial centre of the desired non-
linear welding line, and also relative to the direction in which the first member and the
second member are to be welded, under a state in which the table is inclined, so as to effect
relative movement between the members to be welded and the rotary tool, thereby carrying
out friction stir welding of the first and second members.

Chapter 3: CANVAS
3.1 AEIOU Summary:
3.2 Ideation:

3.3 Product Development:
3.4 EMPATHY Summary:

3.5 Business Model Canvas:

Chapter 4: Methodology and Setup
4.1 Objectives of project:
4.1.1 Joint Strength: The resistance of a material to breaking under tension. We increase
tensile strength of weld joint using appropriate tool profiles and choosing proper input
parameters.
4.1.2 Optimum Parameters: We choose optimum input parameters like speed, feed and depth
of cut for better result.
4.1.3 Tool Profiles: We choose appropriate tool profiles like as circular, hexagonal and
triangle for better result.
4.2 MATERIAL SELECTION:
ALUMINIUM ALLOY:
Aluminium and its alloys belong to the light metals, given their approximate density of 2,70
kg/dm³. For comparison: steel has a density of typically 7,85 kg/dm³. Aluminium has the
largest field of application of the light metals. In 2005, the worldwide annual production of
aluminium was 31 Mt.
• Aluminium is ductile; it can be hot rolled or cold rolled down to thicknesses of 6-7 µm
(foil). It can be extruded down to wall thicknesses of 0,5 mm. It can also be pressed, drawn,
forged, stamped or cast by traditional methods.
• Aluminium is corrosion resistant, and its surface can be further protected from corrosion by
anodising, painting or lacquering.
• Aluminium can be joined by most well-known joining methods, including welding,
brazing, soldering, gluing and riveting.
• The tensile strength of aluminium can be varied from 70 to 700 MPa, depending on the
alloying elements added and the processing. Its ductility and strength can be altered during
the working process to give the material the desired degree of strength. If aluminium is used
in structural components that are subject to stress or bending however, it must be borne in
mind that the metal's rigidity (modulus of elasticity) is not altered significantly by alloying or
hardening. It will always remain about one-third that of steel (EAl = 70 GPa, EFe = 210
GPa).

• Aluminium is light-weight. Used in vehicles, it reduces deadweight and energy

consumption while increasing load capacity. Aluminium has only one-third the density of
steel. • Aluminium is a good conductor of heat. This property is exploited in products such as
cooking utensils and heat-exchange systems.
• Aluminium is an excellent conductor of electricity: its thermal coefficient per weight unit is
twice that of copper. This has made aluminium the most commonly used material in major
power transmission lines.
• Aluminium does not have a ductile-to-brittle transition temperature (contrary to steels),
which explains their use for cryogenic applications.
6xxx series – alloy 6082-T6 (application 1)

The 6xxx series of alloys widely used in transport, engineering and architecture primarily
contain magnesium (< 2%) and silicon (< 2%), which form a strengthening constituent,
magnesium silicide (Mg2Si). The application of fusion welding processes without the
introduction of an appropriate filler metal often results in hot cracking (see §1.2). 6xxx series
alloys generally have a good extrudability.
2xxx series – alloy 2124 (application 2)

The 2xxx series alloys primarily contain copper as alloying element, up to 7%. They are very
strong in age hardened condition and are therefore used for structural purposes (mostly
aerospace applications), but the additional strength achieved is at the detriment of their
durability. Copper in aluminium alloys generally decreases the resistance to general corrosion
and pitting. With proper heat-treatment, quenching, and ageing, these alloys can achieve
moderately good resistance to stress-corrosion cracking (SCC) and other forms of
intergranular corrosion (IGC). The resistance to general and pitting corrosion is strongly
influenced by the copper content regardless of the thermal processing control. These alloys
are significantly affected in heavily polluted industrial or marine environments. Therefore
this group of alloys requires protection in aggressive environments. Moreover, the majority of
2xxx series alloys are considered unweldable by means of conventional fusion welding
processes, due to a high tendency to hot cracking.
5xxx series – alloy 5754-H111 (application 3)

The 5xxx series alloys primarily contain magnesium, up to 6%. Several of these alloys also
contain manganese. Magnesium is a powerful solid solution strengthening element. The 5xxx
series of alloys are the strongest non-heat treatable aluminium alloys, and can only be further
strengthened by cold work. 5xxx series aluminium alloys are considered to have good
weldability with conventional techniques. The magnesium additions generally improve the
corrosion resistance of these alloys, especially in saltwater. The high-Mg alloys (3 to 6%)
possess the highest strength and outstanding corrosion resistance in saltwater environments.
The only drawback is that these can be susceptible to intergranular forms of corrosion,
including exfoliation and SCC, due to the selective precipitation of Mg5Al8 along the
grainboundaries. This can be avoided by using particular tempers and by limiting the
maximum service temperature to 65°C. The 5xxx series have a better corrosion resistance

than the 6xxx series. Unlike the 6xxx series, the 5xxx series can be used in marine conditions
where total immersion in sea water is required.
WE SELECTED ALUMINIUM ALLOY 6082 DUE TO ITS CHARACTERISTICS LIKE,
EN AW-6082 aluminium alloy, also indicated in the EN 573-3 standard by means of

chemical symbols as EN AW-Al Si1MgMn, is a heat treatable wrought alloy, with Mg2Si
being the main precipitation hardening component. For the investigation of application 1, the
alloy was delivered by Sapa RC Profiles as extrusion profiles in the T6-temper according to
EN 515. This temper corresponds to a solution heat treatment followed by artificial ageing.
The geometry of the profile, shown in Figure 9 on the left, shows that the horizontal part has
a thickness of 4 mm, while the vertical is 6 mm. The chemical composition of the 6082 alloy
in this investigation is shown in Table 1 (together with the EN 573-3 requirements for 6082
alloy), and the mechanical properties are given in Table 2 (compared with the EN 755-2
requirements for 6082-T6 extrusion profiles).
Table 1: Chemical composition of 6082 base material compared to EN 573-3
Table 2: Mechanical properties of 6082-T6 base material compared to EN 755-2

4.3 TOOL PROFILES:
We selected different tool geometries like circular, hexagonal and triangular to

analyse their effect on joint properties. We have designed these tools using solid works
software.
1. As here we can see first tool with triangular pin profile.

2. Tool in the middle has hexagonal pin profile.
3. Tool in the right side has circular pin profile.
These tool profiles are made up of material SS 304. These profiles gives different
properties of welded joints. Circular pin profile can be considered as multi edge cutting
tool, the hexagonal pin profile can be considered as six edge cutting tool, the hexagonal
pin profile can be considered as tool with three cutting edges.
The tool profile should be such that which creates less amount of flashes. It should
also prevent formation of chips and the material should be well penetrated by tool to form
the sound weld joint.

4.4 INPUT PARAMETERS:
The main input parameters in friction stir welding are as follow:
 ROTATIONAL SPEED OF TOOL:
The rotational speed of tool also known as machine spindle rpm affects the quality
of joint.
With increase in tool rotational speed the tool, the heat generated by friction also
increases which directly affects temperature at welding position.
Proper temperature is required for desired welding there for the rotational speed of
tool must be selected properly.
 WELDING FEED SPEED:
The welding feed speed which can also be termed as tool advancing speed also
affects the quality of welded joints.
With decrease in tool rotational speed the tool, the time for which tool is in
contact with material increases, so the heat generated by friction also increases
which directly affects temperature at welding position.
Proper temperature is required for desired welding there for the welding feed
speed must be selected properly.

 DEPTH OF CUT( AXIAL FORCE):
The depth of cut in FSW also termed as axial force applied affects the quality of
the welding output.
If we increase the thickness of the material plates to be welded, the required depth
of cut to properly join the material increases, so the required axial force will also
increases.
There is certain limit of axial force that can be applied based on machine
specification. So we have limited range of thickness that can be welded by
machine based on its capability to apply axial force.
We have taken the following input parameters r our project:
parameters I II III
Rotational speed(rpm) 1200 1400 1600
Feed(mm/min) 10 12 14
Depth of cut(mm) 5.0 5.0 5.0
Tool profile circular triangular hexagonal

4.5 TESTING:
To measure the characteristics of welded joints certain tests will be carried out,
 BENDING TESTS:
[Fig. different types of bending tests]

In root bend test the plate is bent from the backside to front side. In face bend test
the plate is bent from the front side to back side. In side bend test the plate is bent
from right side to left side.
 TENSILE TEST:

This test is used to measure the strength of a welded joint. A portion of the welded
plate is locate the weld midway between the jaws of the testing machine. The
width thickness of the test specimen are measured before testing, and the area in
square inches is calculated by multiplying these before testing , and the area in
square inches is calculated by multiplying these two figures. The tensile test
specimen is then mounted in a machine that will exert enough pull on the piece to
break the specimen. The testing machining may be either a stationary or a portable
type. A machine of the portable type, operating on the hydraulic principle and
capable of pulling as well as bending test specimens. As the specimen is being
tested in this machine, the load in pounds is registered on the gauge. In the
stationary types, the load applied may be registered on a balancing beam. In either
case, the load at the point of breaking is recorded.
 COROSION TEST:
The corrosion destroys the welded joints. The joint must be tested under corrosion
test to estimate its life. For this the welded joint is kept in the salt water solution.
Based on the corrosion takes place in specific period of time the corrosion results
can be obtained.
 NICK BREAK TEST:
The nick break test has been devised to determine if the weld metal of a welded
butt joint has any internal defects, such as slag inclusions, gas pockets, poor
fusion, and/or oxidized or burnt metal. The specimen is obtained from a welded
butt joint either by machining or by cutting with an oxyacetylene torch. Each edge

of the weld at the joint is slotted by means of a saw cut through the centre (fig. 13-
5). The piece thus prepared is bridged across two steel blocks (fig. 13-5) and stuck
with a heavy hammer until the section of the weld between the slots fractures. The
metal thus exposed should be completely fused and free from slag inclusions. The
size of any gas pocket must not be greater than 1/16 in. (1.6 mm) across the
greater dimension and the number of gas pockets or pores per square inch (64.5 sq
mm) should not exceed 6.

Chapter 5: Implementation and experimental work
5.1 Friction stir welding on VMC machine

On vertical milling centre machine we have done friction stir welding. The input
parameters as mentioned before were taken for machine process parameters. The program
was generated using Fanuc control programing to describe the tool motion. Tools of different
profiles were mounted on turret of machine.
We have machined our AA 6082 plates in the size of 15 square centimetres and 8 mm
thickness by automatic showing cutter. After cutting of plates we have finished the edges of
plates by rough and smooth files.
Then two plates were clamped on machine bed tightly such that it can withstand the
force of tool motion without dislocating from its size.
First we have taken triangular tool profile and speed of 1200 rpm and feed of 10 mm
per minute. The program was started and the tool penetrated between two plates. At the time
of penetration some chips came out after that the shoulder of tool made the material to stay
inside and to form the good weld as the tool pass from that area.
In following figures the first figure shows welding of two plates on machine, second
figure shows the plates after welding and third figure shows tool after welding.

As we can see in above figure, due to high temperatures around 400 degree Celsius
the tool’s colour on front part was become brownish.
Above figure shows the plates after welding in which we can see the smooth welded
joint. When the tool is taken out at last then it left the hole in the joint.
Like this we have welded other plates with other input parameters.

5.2 Testing of Joints and Results:

The welded plates were given to metallurgical laboratory for tensile strength testing
purpose, we have taken total 9 plates with different input parameters for testing.
Following images shows the testing of joints:
All joints were tested up to failure of joints. The force applied to break them and the
area of cross section was measured and the final tensile strength was calculated for different
joints.
Testing Report:
The report shown here is of the plate welded by triangular tool profile at speed of
1200 rpm and feed of 10 mm per minute.
In testing report we can see that the plate of width 19.50 mm and thickness of 8.03
mm was taken under tensile test, the cross sectional area is shown as 156.59 mm square, the
ultimate load the applied on the joint is 13000 N and we got the tensile strength of 83.0 Mpa
for these conditions.

All the plates were tested like this under tensile strength and we got the results like
this,









Result’s summary:
Tool profile Speed (rpm) Feed Depth of cut Tensile strength

(mm/min) (mm) (MPa)
Triangular 1200 10 5 83.00
Triangular 1400 12 5 82.40
Triangular 1600 14 5 80.06
Hexagonal 1200 10 5 82.1
Hexagonal 1400 12 5 81.9
Hexagonal 1600 14 5 78.00
Circular 1200 10 5 78.2
Circular 1400 12 5 77.5
Circular 1600 14 5 75.7

Chapter 6: Conclusion and Future Scope
6.1 conclusion
Thus by this project, we verify the different input parameters for friction stir welding
and tool geometry to get optimum welded joint property for maximum tensile strength.
At the tool rpm of 1200 and tool feed of 10mm/min we got the maximum strengths
for all three different profiles.
Comparing the joint strength at different profiles we found that maximum weld
strength 83.00 MPa with triangular tool profile and after that with hexagonal tool profile 82.1
MPa and least with circular tool profile 78.2 MPa.
6.2 Future Scope
1. Change tool pin profile to improve weld quality.
2. FSW is done on other types of joint to increase its use, Reduce process time, Safe welding
process and reduce pollution.
3. Design of experiment can be used to characterize the new friction spot welding process.
4. Mathematical model can be developed to predict shear strength of spot welding.
5. Finite element analysis of new friction stir spot welding process can be done to optimize
the weld strength.
6. Further investigations on the forces generated during single and multiple passes for
different alloys at different conditions and for different process parameters might be very
beneficial.
7. Further studies may be done, considering most of the welding parameters, on a wider range
of values. Fatigue analysis, shear tests can be conducted.
8. Higher thickness aluminium plates can be welded by employing double sided FSW. One
can try to use tools made of different materials to improve the quality of the joints.
9. Welding of materials like Copper, Titanium, and magnesium by using friction stir welding
is another area of interest.

Chapter 7: REFRENCES
References:
(1) Karan singla, Dr.Deepak Bhardwaj, VikasBurman “Friction stir

welding”,INTERNATIONAL JOURNAL OF RESEARCH IN AERONAUTICAL AND
MECHANICAL ENGINEERING-(2014).
(2) A. Suresh Babu, C. Devanathan “An Overview of friction stir welding”, International
Journal of Research in Mechanical Engineering & technology-(2013).
(3) Sivakumar, Vignesh Bose, D. Raguraman, D. Muruganandam “Review Paper on
Friction Stir Welding of Various Aluminium Alloy”, IOSR Journal of Mechanical and Civil
Engineering-(2014).
(4) Aleem Pasha M. D., Ravinder Reddy P., Laxminarayana p. And Ishtiaq Ahmad Khan
“INFLUENCE OF PROCESS AND TOOL PARAMETERS ON FRICTION STIR
WELDING – OVERVIEW”, International Journal of Applied Engineering and Technology-
(2014).
(5) M. EL-SHENNAWY, ADEL A. OMAR & M. AYAD “SIMILAR AND DISSIMILAR
FRICTION STIR WELDING OF AA 7075” International Journal of Mechanical Engineering
(IJME)-(2014).
(6) Mandeep Singh Sidhu, Sukhpal Singh Chatha “Friction Stir Welding – Process and its
Variable: A Review”, International Journal of Emerging Technology and Advanced
Engineering-(2012).
(7) C. DEVANATHAN, A. MURUGAN, A. SURESH BABU “OPTIMIZATION OF
PROCESS PARAMETERS IN FRICTION STIR WELDING OF AL 6063”, International
Journal of Design and Manufacturing Technology (IJDMT)-(2013).
(8) Prashant Prakash, Sanjay Kumar Jha, Sree Prakash lal“A STUDY OF PROCESS
PARAMETERS OF FRICTION STIR WELDED AA 6061 ALUMINUM ALLOY”,
International Journal of Innovative Research in Science, Engineering and Technology-(2013).
(9) Hasan I. Dawood, Kahtan S. Mohammed and Zurida A. Wahab“The Effect of Rotational
Speed on Flow Behaviour and Weld Properties in Friction Stir Welding Of Pure Aluminium”,
Advanced Materials Research-(2013).
(10) Renjumohan, N.R. Rajesh, Satheesh Kumar S. “FINITE ELEMENT MODELING FOR
MAXIMUM TEMPERATURE IN FRICTION STIR WELDING OF AA 1100 AND
OPTIMIZATION OF PROCESS PARAMETER BY TAGUCHI METHOD”, International
Journal of Research in Engineering and Technology-(2014).

(11) Ram Kumar, M. Siva Pragash and Saji Varghese “Optimizing the Process Parameters of
FSW on AZ31B Mg Alloy by Taguchi-Grey Method”, Middle-East Journal of Scientific
Research-(2013).
(12) V.L. Srinivas, M. Zammerudhin, M. Ravi Kumar, B. Ravi Sankar and K.
Ravindra“Parametric Analysis of Friction Stir Welding on AA6061 Aluminium Alloy”,
International Journal of Mechanical Engineering and Research-(2013).
(13) L.V. Kamble, S.N. Soman, P.K. Brahmankar“Effect of Tool Design and Process
Variables on Mechanical Properties and Microstructure of AA6101-T6 Alloy Welded by
Friction Stir Welding”, IOSR Journal of Mechanical and Civil Engineering-(2013)
(14) G. Gopala Krishna, P. Ram Reddy & M. ManzoorHussain“Effect of Tool Tilt Angle on
Aluminium 2014 Friction Stir Welds”, Global Journals Inc. (USA)-(2014).
Online Sources:
(15) Global Journal of Researches in Engineering
(16) Int. Journal of Engineering Research and Applications
(17) International Journal of Mechanical Engineering and Research
(18) Science direct
(19) Wikipedia
(20) Free online patents
(21) Indian Patent Office Database
(22) European Patent Office Database

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Team ID: 44124 Friction Stir Welding (2015-2016)

“PARAMETRIC OPTIMIZATION OF FRICTION STIR

Under the guidance of

A Project Report Submitted to

Department Of Mechanical Engineering

Vadodara Institute of Engineering, Kotambi. Page i

Vadodara Institute of Engineering, Kotambi. Page ii

Signature of Students: Signature of Guide:

Patel Purvesh D. (120800119011)

Vadodara Institute of Engineering, Kotambi. Page iii

________________ ________________ ________________

Vadodara Institute of Engineering, Kotambi. Page iv

It gives me pleasure to express my deep sense of gratitude to Mr. Vishhvas B. Rajyaguru

Thank You …by

Vadodara Institute of Engineering, Kotambi. Page v

Vadodara Institute of Engineering, Kotambi. Page vi

4. Methodology and setup

5. Implementation and experimental work

6. Conclusion and future scope 50

Vadodara Institute of Engineering, Kotambi. Page 7

1.1 Introduction to welding

1.2 Welding Processes

1.2.1 Arc welding

There are different types of Arc welding.

Vadodara Institute of Engineering, Kotambi. Page 8

1.2.2 Oxyfuel gas welding

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas

1.2.3 Resistance welding

Vadodara Institute of Engineering, Kotambi. Page 9

3. Low frequency electric resistance welding-Low-frequency electric resistance

1.2.4 Solid state welding:

2. Diffusion welding-Diffusion welding is a solid state welding process which produces

3. Explosion welding- Explosion welding is a solid state welding process in which

1.3 Friction Stir Welding

Vadodara Institute of Engineering, Kotambi. Page 11

[fig.: friction stir welding process]

1.3.1 Working Principle

Vadodara Institute of Engineering, Kotambi. Page 12

1.3.2 Process Parameter

Vadodara Institute of Engineering, Kotambi. Page 13

1. Shipbuilding and Marine Industries:

 Panels for decks, sides, bulkheads and floors

 High speed trains.

 Electric motor housings (in production),

Vadodara Institute of Engineering, Kotambi. Page 14

1. Low heat distortion.

7. Generally good weld appearance and minimal thickness under/over-matching, thus

8. Low environmental impact.

1. Exit hole left when tool is withdrawn.

Vadodara Institute of Engineering, Kotambi. Page 15

1.4 Problem Statement

Vadodara Institute of Engineering, Kotambi. Page 16

Chapter-2 Literature survey

2.1 Review of Technical Research Papers

Vadodara Institute of Engineering, Kotambi. Page 17

AUTHOR: Dr.T.Parameshwaran Pillai, S.K.Selvam

Vadodara Institute of Engineering, Kotambi. Page 19

Vadodara Institute of Engineering, Kotambi. Page 20

Vadodara Institute of Engineering, Kotambi. Page 21

2.2 Patent search activity