Friction stir processing (FSP) is used to transform a heterogeneous microstructure to a more
homogeneous, refined microstructure. There are several possible methods available which can be
applied to a variety of material shapes and sizes.
In many cases, the re-processed areas have superior strength and formability than the parent
material, e.g. aluminium castings can be processed to consolidate voids, or extrusions can be
improved in highly stressed areas. In combination with superplastic forming, FSP offers the
potential to form complex-shaped parts at higher strain rates and in section thicknesses not
possible using conventional superplastic processing.
The process advantages result from the fact that the FSW process takes place in the solid phase
below the melting point of the materials to be joined. The benefits include the ability to join
materials that are difficult to fusion weld, for example, 2XXX and 7XXX aluminium alloys,
magnesium and copper. Friction stir welding can use purpose-designed equipment or modified
existing machine tool technology. The process is also suitable for automation and is adaptable
for robot use.
Other advantages are as follows:
Low distortion and shrinkage, even in long welds
Excellent mechanical properties in fatigue, tensile and bend tests
No arc or fumes
No porosity
No spatter
Can operate in all positions
Energy efficient
One tool can typically be used for up to 1000m of weld length in 6XXX series aluminium
alloys
No filler wire required
No gas shielding for welding aluminium
Some tolerance to imperfect weld preparations - thin oxide layers can be accepted
No grinding, brushing or pickling required in mass production
Can weld aluminium and copper of >75mm thickness in one pass.
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. This offers significant advantages compared to riveting and machining from
solid, such as reduced manufacturing costs and weight savings. Longitudinal butt welds in Al
alloy fuel tanks for space vehicles have been friction stir welded and successfully used. The
process could also be used to increase the size of commercially available sheets by welding them
before forming.
The friction stir welding process can be considered for:
Wings, fuselages, empennages
Cryogenic fuel tanks for space vehicles
Aviation fuel tanks
External throw away tanks for military aircraft
Military and scientific rockets
Repair of faulty MIG welds
TWI FSW Systems
TWI uses a comprehensive range of FSW machines and peripheral equipment to research and
develop most industrial applications. Component thicknesses from 0.3mm - 75mm have been
joined successfully.
SuperStir
The machine has a vacuum clamping table and can be used for non-linear joint lines.
Sheet thickness: 1mm - 25mm aluminium
Work envelope: 5 x 8 x 1m
Maximum down force: 60kN (6t)
Maximum rotation speed: 5000rev/min
PowerStir
This machine was selected to extend the boundaries in the research and development of thick
section FSW. The machine is one of the largest FSW machines in the world with over 130KW of
spindle power. It has 12 programmable machine axes, a maximum down force of 15 tonnes and
operates over an area of 6m x 3m. The machine has 3D welding capability and features an
opposed welding head - a second welding head located directly beneath the upper head, which
allows simultaneous, twin-sided welding to be performed. This offers the potential to weld
materials up to 100mm thick in one pass.
Precision Spindle
The unique feature of the machine is its high concentricity spindle. This precision spindle allows
research into the new range of ceramic tools being developed for friction stir welding of
materials which have higher softening temperatures than those metals traditionally welded by
FSW. Higher softening temperature materials include steels, stainless steels, titanium and nickel-
based alloys.
This fully instrumented machine is capable of producing a down force of 10 tonnes and has a
working envelope of 2m x 0.6m
FlexiFab System
This system combines the power of friction stir welding technology with the flexibility of a
robot. This provides versatility not before associated with friction stir welding, with the ability to
weld in any position and follow complex 3D weld paths, with the possibilities only limited by
the imagination of the engineer.
The machine has a working envelope of 5 metre diameter and can be physically repositioned to
cater for larger components.
The system incorporates a comprehensive data logging system to monitor and control the
important FSW process parameter.
The robot will also provide the platform to develop the variant of FSW, Friction Spot Stir
Welding which is solid state welding alternative to conventional spot welding.