Friction stir welding evolution, hybrid technologies and shoulder shape

• Published in: International journal on interactive design and manufacturing 2023-08, Vol.17 (4), p.1443-1458
• Main Authors: Vinith, B., Dharshan, S. A. Dhanush, Aravind, S., Singh, Bipin Kumar
• Format: Article
• Language: English
• Subjects: Alloy steels; Aluminum base alloys; Aluminum composites; Automotive parts; CAE) and Design; Computer-Aided Engineering (CAD; Copper; Copper base alloys; Dissimilar material joining; Dissimilar materials; Dissimilar metals; Electronics and Microelectronics; Engineering; Engineering Design; Friction stir welding; Gases; Heat affected zone; Industrial Design; Instrumentation; Magnesium alloys; Mechanical Engineering; Metals; Process parameters; Review; Shipbuilding; Steel alloys; Tensile strength; Titanium alloys; Weight reduction; Weld strength; Welding parameters
• ISSN: 1955-2513; 1955-2505
• DOI: 10.1007/s12008-023-01208-9

Friction stir welding (FSW) are inherently used for joining of dissimilar metals in manufacturing industries, especially in aerospace and automobile parts, but the investigation for optimum condition remain inconclusive. Hence, this study reveals the efficacy of FSW process alongside hybrid technologies towards welding of similar and dissimilar materials like aluminum, copper, and steel. The optimum condition for maximum welding strength obtain by FSW process is reveal as rotational speed around of 1000–1400 rpm, transverse speed in between 40 and 60 mm min −1 and tilt angle around 2°. Apart from said parameters some researchers also found that the high values of process parameters have beneficial effect on the weld strength. In addition with process parameter, the annealing effect provided by allied technology fuelled the weld strength to maximum, due to formation of equiaxed fine grain in stir and heat affected zone. The maximum welding strength compile through various articles is found as 250–300 MPa for aluminium alloy, 350–500 MPa for copper alloy whereas, for steel alloys more than 500 MPa. The review also observed there are three factors i.e. concave shape at the end of shoulder, the ratio of shoulder diameter to pin should be less than 3 and shape of shoulder cylindrical, triangular and hexagonal can be prefer to achieve maximum weld strength. Finally, the conclusion provides an insight towards optimum conditions that can be apply in aerospace as well as automobile sectors for getting high productivity.