Friction Stir Welding Demonstration - Manufacturing Technology, Inc.

[NOCERINale]

How i can do a good analisys of the grain???

[dillonbakkedotcom]

nice editing ;)

[TSalvalagio]

Doesn't it create a hole in the section? I mean, under the weld, isn't it hollow?

[dougw246]

@TSalvalagio - There is often a hole, the size of the pin at the end of the tool, at the end of the weld. There are some strategies to eliminate or minimize what is called the retraction defect. The simplest strategy is to end the weld in an area where the defect is not a problem or use a runoff tab that is cutoff. also, there is a retractable pin tool technology we use that retracts the pin into the shoulder at the end of the weld, eliminating the defect.

[JAPudas]

OMG You have got 2 be BSing me :O

[Morinoidate18]

Thanks!! Now I got a more better idea of how this welding works!!

[MrMickoo7]

THANKS MAN,YOU SAVE ME,THIS IS ONE OF THE QUESTION ON MY EXSAM IN MONDAY..NICE VIDEO...

[urmesty]

recently i've done some welding on an aluminum plate. I've encountered some splatter problem. can you give some tips on hw to prevent splattering.

[Knnniggit]

I was like

-_-

And then I was like

O_o

I had never heard of friction stir welding before. That's just bizarre.

And BTW, those hydraulic clamps = cool.

[citanon]

Thanks dougw246. How do you get rid of the hole at the end，or is that not necessary?

[dougw246]

@citanon, There will always be an extraction defect with stir welding unless you incorporate retractable pin tool technology into the machine. It is sometimes not a problem to have the extraction defect if you can locate it on the part where it is not offensive or run-out tabs can be used to locate the defect off the part.

[citanon]

@dougw246 Makes sense. I'm guessing that for the first weld in the video, the machine stopped at a run-out tab?

Thanks for posting this video and the explanation. I'm a material scientist by training but I've done so much nanotechnology that I forgot how cool "normal" material science can be.

[Munty102]

I dont get it it. Wont the bonding just occur on the surface but the interior remain seperated?

[dougw246]

@Munty102 This is a lap weld. The pin tool penetrates the top layer of material and part of the second layer of material. Thus, stirring together the two contacting surfaces. Our website has a friction stir welding joint geometry section with pictures that illustrate this.

[citanon]

Is the drill head itself also pressing down on the metal with high pressure?

[dougw246]

@citanon, yes there are very high forces involved in friction welding. The force is dictated by the material type. The force to stir weld aluminum is much less than something like steel.

[Mikyzo86]

Why at 7:55 you intentionnally cover the remaining hole of the tip with your hand??

It is also covered at the beginning of the welding by the clamps....

[dougw246]

@Mikyzo86, no reason I can think of. There will always be an extraction defect with stir welding unless you incorporate retractable pin tool technology into the machine.

[gustvoantonio]

EXELENTE....

[clawsofangels]

Gotta love that music, Sounds like "Adult-movie-background music" LOL

[TheBilalKhan]

i know there are different ranges of these variables for different thicknesses of different alloys but what are the ranges for Aluminum 5XXX series alloys

[DrFG311]

I think this would fall under "proprietary information". They didn't just stumble across those parameters, they likely had to set up a design of experiments to ascertain that info. I spent a few years doing just that.

[TheBilalKhan]

hey i need to know about the the Feed speed (lateral speeds) rotational speeds (of the tooling aka Pin) and the maximum pressure (KN) required to achieve a sound weld ...thanx any help will be appreciated

[welderman27]

thats incredible

[welditup85]

Also, what is the copper bent tubing? is it blowing compressed air to keep the pin cool or is it acting like a vacuum to suck up metal flakes? Maybe a shielding gas?!

[dougw246]

The copper tubing is for colling fo the pin tool. Normally shielding gas is not needed with this process.

[welditup85]

Dude, I'm a student welder with a welding job. What does coiling for the pin tool mean? I know you may understand no problems but me... I'm lost.

[flanksteak5]

Cooling

[welditup85]

The music had to be turned off, it was absolutely horrible. The FSW process is so cool though and I liked the video. Instead of some new age bull**** music why not talk about what your doing, what the process is doing, and why it is doing that. Your responses are all great on telling us what FSW is; however, why not give a short video on that. Try calling it Friction Stir Welding: 101. I'll be looking for it!

[dougw246]

Thank you for the comments. There is a video that is shorter and narrated called, "Narrated Friction Stir Welding Demonstration - Manufacturing Technology, Inc." Feel free to let me know if that meets the need.

[monimstarfox]

Does the very tip penetrate the metal?

and if it does how does it make the weld

[dougw246]

Yes, the tip (aka pin) does penetrate the metal. As the pin rotates, friction heats the surrounding material and rapidly produces a softened "plasticized" area around the pin. As the pin travels forward, the material is stirred together by the pin, the material behind the pin is forged under pressure from the shoulder and consolidates to form a bond.

[monimstarfox]

wow thats quite amazing

in my highschool shop classes we learn to weld but i wonder if we will ever get to friction welt it seems very interesting. I have a question they say friction welding doesn't reduce the properties of the metal unlike welding but doesn't friction welding also heat up the material which also alters its characteristics?

[citanon]

@dougw246 Excellent. How do you get rid of the final hole after you pull out the pin?

[dougw246]

@citanon, the pin extraction defect is one of the technical hurdles with stir welding. It is possible to use a retractable pin tool to minimize this defect. The tool slowly retracts into the shoulder of the stir tool near the end of the weld. This process will eliminate the extraction defect, but it is expensive to incorporate on the machine.

[conoba]

Never even heard of it before.

What are the advantages of that process?

[dougw246]

Following are advantages of FSW: - Forge quality Joint, weld strength is usually as strong or stronger than parent material - Low energy input - No consumables or fillers - Very narrow heat affected zone - Low distortion, even in long welds - Excellent mechanical properties as proven by fatigue, tensile and bend tests - No arc - No fume - No porosity - No spatter - Low shrinkage - Can operate in all positions - No gas shielding for welding aluminium - No welder certification required

[YoungJim409]

What does the little protrusion on the end of the tool do?

[dougw246]

The protrusion, know as the pin, has two purposes. It generates heat for the welding process and it stirs the plasticized metal together to join the materials.

[PodeCoet]

That's pretty neat!

[Musti087]

tnx 4 sharing!