Introduction to FSW

Friction Stir Welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. It was invented by Wayne Thomas at The Welding Institute (TWI) in 1991.

The Process

The FSW process involves the following steps:

1. A rotating tool is plunged into the joint line between two pieces of sheet or plate material.
2. The tool is then traversed along the joint line, creating frictional heat that plasticizes the material.
3. The material is mechanically intermixed, and as it cools, it forms a solid-phase bond between the workpieces.

Applications

FSW is used in various industries including aerospace, automotive, shipbuilding, and railways. It is particularly useful for joining aluminum alloys, which are difficult to weld using traditional methods.

Advantages

• Produces high-strength welds
• Low distortion and shrinkage
• No filler material or shielding gas required
• Environmentally friendly

Disadvantages

• High initial setup cost
• Limited to linear welds
• Requires rigid clamping of workpieces

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