1. Welding Friction Stir Welding (FSW) Copyright © Texas Education Agency, 2012. All rights reserved.

2. Objectives… Identify the tools & equipment used with FSW Describe the process of FSW List the benefits and issues of using FSW Copyright © Texas Education Agency, 2012. All rights reserved.

3. Short History Friction Stir Welding was developed in England in the late 1980’s and patented in 1991. This means that in order to use the process, you must obtain permission. So why bother? Because it has some unique advantages that no other welding process, right now, have. Copyright © Texas Education Agency, 2012. All rights reserved.

4. WHAT IS FRICTION STIR WELDING? Copyright © Texas Education Agency, 2012. All rights reserved.

5. Defined… FSW is a welding process that joins to different metals by fusing them from the heat from a rotating tool. Copyright © Texas Education Agency, 2012. All rights reserved.

6. ADVANTAGES & DISADVANTAGES Copyright © Texas Education Agency, 2012. All rights reserved.

7. Advantages Superior welds Low distortion & shrinkage Less stress Energy efficient No fume, porosity, spatter Great mechanical properties Copyright © Texas Education Agency, 2012. All rights reserved.

8. Disadvantages Cannot make fillet welds There is a keyhole at the end of the weld Pieces must be rigidly clamped together Requires a backing bar Copyright © Texas Education Agency, 2012. All rights reserved.

9. THE PROCESS Copyright © Texas Education Agency, 2012. All rights reserved.

10. The Process Rotating tool Central pin/probe Heats Plasticizes Moves tool along the joint Movement pushes material to the rear, eliminating interface. Copyright © Texas Education Agency, 2012. All rights reserved.

11. Uses Original applications for FSW include: Welding of long lengths of material in the aerospace, Shipbuilding Railway industries. Formula 1 race cars Other examples include large fuel tanks and other containers for space launch vehicles, cargo decks for high- speed ferries, and roofs for railway carriages. Copyright © Texas Education Agency, 2012. All rights reserved.

12. QUESTIONS? Information courtesy of TWI & other sources. Copyright © Texas Education Agency, 2012. All rights reserved.