(Fu

AUTHOR
et al.,
2015)
NO
1
Dr.Ayad M. Takhakh
2012
Asmaa M. Abdullah

TITLE

The Optimization Conditions of Friction Stir

Welding (FSW) for Different Rotational
and Weld speeds

JOURNAL

College of Engineering Journal (NUCEJ) Vol.15

No.2, 2012 pp.187 - 196

Al 3003-H14

Obj:
The effect of welding parameters on mechanical properties of aluminum alloy 3003 H14 Friction stir-welded (FSW) joints were investigated in
the present study.
Experimental Setup:
-Al 3003-H14 was selected.
-two aluminum plates 3mm in thickness, 100 mm length, and 150 mm width
-Using Hermen miling machine
-The length of the stirrer was same as the required welding depth.

Clamping ficture utilized in order specimens to be welded

-22 mm shoulder diameter and 7mm pin diameter,
-height of the pin equal to the distance that plunged in the plate and it was 2.9 mm of the sheets processed.
-The forces generated using this tool especially during the penetration of the tool into the work piece, were very high and caused excessive
machine vibration.
-Then the pin of the tool is tapered (Fig. 4) in order to reduce the initial high forces during plunging operation, the welding tool was made of tool
steel X38 as the chemical composition shown in table 3.

Result:
-The friction stir welding joints were shown in Fig. 5.
-Visual inspection shows different results of welding shapes where some welds shows presence of flash as shown in Fig.6.
-Because of the plunging depth of the tool this can be avoided by controlling it which must be little more than the plate thickness
-Tunnel defect was found at the intersection of weld nugget and thermo-mechanically affected zone due to high rotational speed and travel speed
-By optimizing rotational speed 1500 rpm and travel speed 80 mm min this defects was avoided
-Others show presence of pin hole this easily removed using filler and getting finer shape, Fig.6 presented the visual inspection of welding results.
[20-21]

1500rpm 80mm/min
-A simple tensile test was carried away using a tensile testing device,
- the strain was read using a dial gauge to read the strain in load direction,
- the test specimens of 3003-H14 aluminum alloy were prepared according to the ASTM D638M-89 standard specimen
-Welding processes were carried out with four different Weld speeds and four different rotational speeds as shown in table 4.
-Tensile and hardness tests for FS welds done at room temperature, tensile results shown in Fig 9.
-The best result obtained at 1500 rpm and 80 mm/min and the efficiency 89 % of the base metal Al 3003 H14.
-Micro hardness test were prepared in order to characterize the hardness profile in the vicinity of the weld affected area i.e. NZ, TMAZ, and HAZ
in the FSW specimens.
-Also the hardness profiles are extremely useful, as they can assist in the interpretation of the weld microstructure and mechanical properties.
-Each specimen was tested by dividing it into regions each point tacked 30 second with hardness Vickers (HV) then the reading has been recorded
and measuring the other point respectively

-results shows increasing in hardness from center to the parent metal and the lowest value is observed in the nugget zone because that Al 3003 is a
strain hardened tempers of the non-heat treatable alloys
-The hardness results shown that, in the strain hardened tempers of the non-heat treatable alloys, the recrystallization occurs in the nugget zone
during FSW, would eliminate some or all of the cold work effects. This, in turn, would lead to nugget softening and the development of as welded
hardness distributions are similar to that depicted in Fig. 11 which shows the hardness distribution of strain hardened tempers of the non-heat
treatable alloys [22]. It should be noted that a local material softening occurs in the weld because of the thermal action of the welding process; in
particular a localized softening in the NZ is observed. Note that results will show
increasing in HV from center to the parent metal and the lowest value is observed in the nugget zone.
The joint strength was investigated with tensile tests, to give an average value of the ultimate tensile strength equal to the 89% of the UTS of the
parent material, again fractures in many samples were occurred nearby the HAZ, in correspondence to the lowest values of micro-hardness the
micro-hardness was obtained along the transverse joint section, indicating a strong improvement of the joint mechanical characteristics [23],
Intro:
Friction stir welding (FSW) is a relatively new technique for joining aluminum alloys [1];
FSW is a highly important and recently developed joining technology that produces a solid phase bond. It uses a rotating tool to generate
frictional heat that causes material of the components to be welded to soften without reaching the melting point and allows the tool to move
along the weld line. Plasticized material is transferred from the leading edge to trailing edge of the tool probe, leaving a solid phase bond
between the two parts [2].
The process is carried out by plunging a rotating FSW tool into the interface of two rigidly clamped sheets, until the shoulder touches the
surface of the material being welded, and traversed along the weld line. The frictional heat and deformation heat are utilized for the bonding
under the applied normal force[3].
Friction stir welding structures and properties, the influence of axial load, and the effect of position of the interface with respect to the tool

axis on tensile strength of the friction stir welded joint have been studied [5-7].
Welding parameters and stirrer geometry effect, and tool effect on FSW have been studied [8-9].
The typical welding defects and welding material aspects and the Effect of Friction Stir Welding on Dynamic Properties of some aluminum
alloys also have been investigated [10-12].
Other investigations have been studied the fatigue of friction stir welding and studied their properties, and crack propagation of fatigue on
friction stir welding [13-19].
Conclusion
The influence of FSW parameters on the tensile and microhardness properties of FS-welded 3003 H14 Al alloy at various FSW conditions was
examined in the present study.
1. Tunnel defect was found at the intersection of weld nugget and thermoMechanically affected zone due to high rotational speed and travel speed.
2. The design of tool with tapered pin was suitable to avoid tool breakage
3. Mechanical properties of FS welded aluminum alloy 3003 H14 are influenced by process parameters. Hardness drop was observed in the weld
region. The softening was mostly evident in the nugget zone because that Al 3003 is a strain hardened tempers of the non-heat treatable alloys.
The optimum efficiency for joints of the using parameters of FSW founded at 80 mm/min weld speed and 1500 rpm rotation speed it reaches to
efficiency 89% of the ultimate tensile stress of the base metal.
NO
2
2008

AUTHOR
Saad Ahmed Khodir
Toshiya Shibayanagi
(Khodir & Shibayanagi, 2008)

TITLE
Friction stir welding of
dissimilar AA2024 and AA7075
aluminum alloys

JOURNAL
Materials Science and Engineering B 148 (2008) 8287

Objective:
-to investigate the effects of welding speed and fixed location of material on microstructure, hardness
distribution, and tensile properties for dissimilar of 2024-T3 to 7075-T6 Al alloys joints produced by FSW.
Experimental Setup:
-Plates 3mm thick of 2024-T3 and 7075-T6 A
-tool of 12mm diameter shoulder and 4.0mm diameter threaded pin.

-Rotation speed was kept constant at 20 s1(1200rpm) and welding speed was set at 0.7(42), 1.2(72), 1.7(102) and
3.3 (198) mm/s
-Microstructures of various regions of welds were observed in the cross-section of the joint by optical microscopy.
Result:
-the rise in welding speed tended to the formation of kissing bond and pores especially when the 2024 Al alloy plate
was located on the retreating side.
-Onion ring patterns were formed and characterized by bands of different equiaxed grain sizes and heterogeneous
distribution of alloying elements
-Maximum tensile strength of the joints of 423MPa was achieved at a welding speed of 1.7 mm/s when 2024 Al alloy
plate was located on the advancing side.
Intro:
Friction stir welding (FSW) is a solid-state joining process invented at TheWelding Institute (UK) in 1991 [1,2].
The jointing process proceeds in a solid-state where temperature during welding is relatively less than the
melting point of welded metal [35].
The heat generation caused by the friction between the welding tool and weld metal makes the surrounding
material around the tool is soft and allows the tool to move along the joint line [5].
Dissimilar joints of 2024-T3 to7075-T6 Al alloys are required for aerospace application to optimize mechanical
and chemical properties.
NO

AUTHOR

TITLE

JOURNAL

Sadeesh
Studies on friction stir welding of AA 2024
Procedia Engineering 75 ( 2014 )
and AA 6061 dissimilar
Venkatesh Kannan
145 149
2014
metals
Rajkumar
Avinash
Arivazhagan
Devendranath
Ramkumar
Narayanan
(Sadeesh et al., 2014)
Objective:
-The joining of dissimilar AA2024 and AA6061 aluminium plates of 5mm thickness
-Five different tool designs have been employed to analyze the influence of rotation speed and traverse speed over the microstructural and tensile
properties
-Optimum process parameters were obtained for joints using statistical approach
-Effect of welding speed on microstructures, hardness distribution and tensile properties of the welded joints were investigated
3

Experimental Setup:
-5mm thick plate of AA 2024-T4 (Al-Cu alloy) and AA 6061-T4 (Al-Mg-Si alloy); dimension 100 50 mm
-welding tool used : AISI H13 tool steel which has high resistance to thermal fatigue
-AA2024 was placed on the advancing side due to its higher mechanical strength and the tool pin was positioned at centre of joint line
Introduction:
Aluminium alloys, AA6061 and AA2024, are widely used in many emerging fields of aerospace industry and marine industry in the
construction of frames, pipelines and storage tanks. Dissimilar joining process is considered as a challenging one when compared to similar
welding process, due to variation in chemical composition and mechanical properties of the base materials [1-3].
Since fusion welding of dissimilar aluminium is tedious, Friction Stir Welding (FSW) process is widely used for welding of dissimilar
materials, where the formation of secondary phase is absent since the temperature involved in this process is well below the melting
temperature of base materials. Previous studies indicate the optimum parameters for welding of dissimilar aluminium alloys, with rotation
speed of 600-1000 Rpm, traverse speed around 15-40 mm/min and D/d ratio of 3:1 [4].
Better mechanical properties are obtained when harder material is placed on the advancing side and softer material in retreating side [5,7].
Since tool geometry plays a vital role in dissimilar welds,different tool profiles are widely being used these days. Tool pin profiles such as
threaded, squared and triangular are efficient to transfer the material from top to bottom of the joint and vice versa by stirring action [6].
Result:
-Tool profile influenced the weld quality
-at 710rpm,28mm/min D/d ratio of 3, cylindrical pin is the most efficient

-6mm squared pin (1000rpm,40mm/min) produced better mehanical properties

-best tool profile - cylindircal threaded and squared pin profile

NO
4

AUTHOR
TITLE
JOURNAL
J. Mohammadi
FSW joint of dissimilar materials between
Y. Behnamian
AZ31B Mg and 6061 AL alloys : Misrostructure
2015
A. Mostafaei
studies & mechanical characterizations (lap
H.Izadi
joint)
(Mohammadi et al., 2015)
Objective:
-To investigate the (rotation and travel speeds) on microstructure of the joints welded between AZ31B & AL 6061 using SEM-EDS.
-To perform tensile test (mechanical test) to determine whether tool rotation and travel speed affect the result
Experimental Setup:
-AL 6061 alloy and AZ31B Mg alloy
-Thickness 0f 2.3 and 3.1mm
-Dimension 90mm in length & 20mm in width
-AZ31B on top and AL 6061 at the bottom
-Tapered threaded pin & tilt angle 3
-Rotation speed W / Travel speed V (weld pitch)
1400/40, 1250/31, 900/25, 700/20 & 560/16
Results:
-Lap joints FSW btween Al & Mg were improved tensile strength & ductility
-Increasing rotation & travel speed in a constant ratio 1400mm/min & 40mm/min resulted in higher tensile and ductility of the joints
NO
5

AUTHOR

TITLE
Effects of pin angle and preheating T
distribution during FSW operation
Copper C11000

JOURNAL
Journal Of Transactions of Nonferrous Metals Society
of China

R.Keivani
B.Bagheri
2013
F. Sharifi
M. Ketabchi
M. Abbasi
Objective:
-to investigate the effects of pin angle and preheating on the temperature distribution of copper C11000 during FSW process.

Experimental Setup:
-material : Copper C11000 (dimension : 60mmx20mmx3.1mm)
-Welding tool : SKH9 high speed steel
-FEM modelling by Abaqus to do thermal analysis
-Lagrangian adaptive mesh domains to analyze transient problems with large deformation.
Different mesh element assigned to different region
Smallest mesh element in the region of weld
Result and discussion
-numerical data do not confirm the exp result exactly
-the differences between this two are acceptable
-the locations that difficult to det for T, cost and time reduction are the advantages of simulation compare to exp
-Pin angle effect :- the increment of pin angle results in expansion of contours (T around the weld position) increased
:- the enhancement of contact area between the pin and the w/piece and corresponding further subjection of softened material underneath
the shoulder to
Extrusion as the tool rotates and traverses
-The T increases as the pin angle enhances and temperature decreases as the weld line decrease towards normal path
-Preheating effect the effect of T on mechanical prop (yield strength); as the initial T increases ,the yield strength also increases.
-less forming force req for deformation during fsw process & consequently less friction stress and heat are generated.
-for the workpiece initially heated to low T, the generated heat is high & for the w/piece initially heated to high T, the produced heat is low
-Therefore, the effect of 2 parameters (initial T & produced heat during FSW process) the plunging step counterbalance each other and diff
between T histories are low.
-Although preheating results in high initial T of w/piece but as lower heat is produced during welding process, it does not affect the T distribution
along the weld line largely.
Conclusion:
-As the pin angle increases (due to increment of friction which has the decisive effect on generating heat during fsw process), T around the weld
line enhanced.
-the effect of preheating on T distribution along the weld line due to effect of generating heat during FSW process is minor.

NO
6
2015

AUTHOR

D.Trimble
G.E ODonnell
J.Monaghan
Objective:

TITLE
Characterisation of tool shape and
rotational speed for increased speed during
FSW of AA2024-T3 (butt joint)

JOURNAL
Journal Of Manufacturing Process

-to characterize the effects of tool shape and rotational speed on increasing the welding speed during the FSW OF 4.8mm thick AA2024-T3
plates.
Experimental Setup:
-material : AA2024-T3 plates (360mmx80mmx4.8mm)
-Welding tool : AISI H-13
-Pin shape : cylindrical, triflute and square
-Shoulder design : concave & scroll
Result and discussion
-scroll shoulder design enabled higher welding speed compare to concave
-the triflute pin is the most effective shape for tool pin due to unique design of 3 flute helical ridge design which increases the amount of plastic
deformation and stirring of the w/piece to process w/piece material at an increased rate.
-Welds produced at 450rpm provide optimal amount of plastic deformation & frictional heating at high welding speeds.
-Welding at rpm below this opt value caused insufficient material deformation to form fully consolidated weld. Whereas welding at rpm above opt
value resulted in excessive plastic deformation and stirring leading to the occurring of small voids in the w/piece.
-Result also confirmed that increasing welding speeds cannot simply achieved by increasing the rotational speed
-To achive good weld quality at high welding speed of 355mm/min by utilizing effective parameters and tooling
-Welds produced at this speed achieved tensile strength of 93.9 of parent material with relatively good ductility and the presence of no internal/
surface defects

NO
7
2014

AUTHOR

TITLE
Microstructure and Mechanical Properties Of
AZ31B Mg Alloy By Friction Stir Welding

JOURNAL
Journal of Procedia Materials Science

S. Ugender
A. Kumar
A. Somi Reddy
Objective:
-to investigate the effects of rotational speed and tool materials (HSS & S) on mechanical properties of FSW of AZ31B Mg alloy
Experimental Setup:
-material : AZ31B Mg alloy (240mmx60mmx5mm)
-Welding tool : High speed steel & stainless steel (SS)
-Diameter of tool shoulder (D) is 18mm
-Pin diameter (d) 6mm & Pin length 4.8mm

Result and discussion

-Effect of rotational speed
Tensile properties- (i.e SS material)RPM <900( tensile strength lower), RPM 900-1120 (tensile strength increased), RPM >112O (tensile
strength decreased)
Higher rpm resulting in higher input/unit length and slower cooling rate in the FSW zone causes excessive grain growth. It also causes expensive
release of stored materialsto the upper surface. At 1120 rpm , tensile strength higher becoz of optimum heat generation which is sufficient to cause
free flow of plasticized material & adequate mechanical working.
Hardness at 1120rpm, 40mm/min its recorded higher hardness (75Hv) in the stir zone.
2 main reasons for improved hardness which are the grain size is much finer than base metal(grain refinement plays a vital role in material
strengthening) and the small particles of IMC are also a benefit to hardness improvement.
Impact toughness 8J at unwelded base metal & reached max 6J at stir zone (1120rpm).
This is due to opt heat generation which is sufficient to cause free flow of plasticized material.
Microstructure at stir zone, the coarse grain of base metal changed to fine grain. At 1120rpm (40mm/min) and SS tool contains finer
grains than other joints.
This lead to the higher tensile strength at that joints compared to other joints. The relation between rpm, tranverse speed and input heat which
effect on the impact value seems to be compound and depend on material properties being welded. Grain are relatively smaller in retreating side
compared to advancing side.
Conclusion :
-Tool material and rotational speed have been identified as an important parameters that affect the stir zone microstructure and properties of FSW
process.
-SS tool material provided fine grain microstructures & better mech prop as compared to HSS
-Low RPM provided high stirred zone microhardness value compare to base material.
-The joint fabricated at 900rpm have shown lower ultimate tensile strength, yield strength,% of elongation, weld nugget hardness & impact test
compare to 1120 rpm
-Also at 1400 rpm and 1800 rpm also lower tensile strength compared to 1120 rpm
-The joint fabricated at 1120 rpm exhibited superior tensile strength properties.
NO
8
2014

AUTHOR
R.K Kesharwani
S.K Panda
S.K Pal\
(Kesharwani et al., 2014)
Objective:
-to optimize the parameters in FSW

TITLE
MultI Objective Optimization Of FSW Parameters
For Joining Of Two Dissimilar Thin Aluminium
Sheets (butt joint)

JOURNAL

Experimental Setup:
-material : AA5052-H32 & AA5754-H22 (200mmx100mmx2mm)
-Backing plate high carbon steel plate
-Welding tool : SS 316 (stainless steel)
-Pin diameter (d) 1/3 of D (Pin length : 1.8mm)
-Rotational speed : 1120,1400,1800 (rpm)
-Translational speed : 50,125,200 (mm/min)
-Tool shoulder diameter : 12,15,20
-Tool pin profiles : circular, triangular, square
-Using Taguchi L9 orthogonal array to reduce no of exp. (4 factors & 3 levels)
-Performed tensile test and weld microstructure identification
Result and discussion
-Tool rotational speed most significant factor. Followed by tool pin geometry, tool shoulder diameter
-Effect of worktable feed insignificant factor
-Predicted grey relation grade =0.874251356411638
-Existing grey relation grade at opt condition = 0.97263 . so the diffrnce only 0.1. This variation occurs due to neglecting the nonlinear effect in
four factor level Taguchi L9 orthogonal array.
Conclusion :
-Optimum parameters for welding of AA5052-H32 & AA5754-H22 dissimilar 2.0 mm thin are (1800rpm, 50mm/min, 20mm of tool shoulder
diameter & square pin geometry) that giving maximum weld strength (UTS :175 MPa and max elongation 13.854)
-Location of fracture in uniaxial tensile test of the welded sample using opt parameters is at TMAZ (relatively high strength of the weld NZ
NO
9

AUTHOR
TITLE
JOURNAL
Suyash Tiwari
Parametric Analysis Of FSW
H. Chelladurai
(butt joint AL-6063)
Ashish Kumar Shukla
Objective:
-to achieve high quality strength of the welded joint by controlling the parameters when welding is taking place by applying statistical analysis
(RSM).
Experimental Setup:
-material : aluminum alloy 3mm thickness
-Pin length : 2.8mm, 1.9mm and 1mm

-Rotational speed : 1600, 1200, 800(rpm)

-Translational speed : 100,80,60 (mm/min)
-Tool shoulder diameter : 20,18,16
-Workpiece material: Al 6063 (Thermal conductivity & melting point : 201 W/m.-K , 928 K/654.85)
-Backing plate STAINLESS STEEL thickness 2mm (grade 202) (Thermal conductivity & melting point : 16.3 W/m.-K , 1727 K/1453.85)
-Fixture/clamp material mild steel
Result and discussion
-More pin length increased, leads to penetration and produces more frictional heat throughout the thickness of w/pieces which plasticizes the
material.
-Tool RPM effect
if tool rpm too low, the frictional heat is not enough to cause plasticized flow. The metal in the weld zone cannot diffuse and
recrystallize. Hence there is void in the welded joints.
If tool rpm too high, the T of material beneath the tool shoulder & around the probe will exceed the melting point & the welding
will no longer be a solid state welding
An increase in tool rpm increases the frictional heat which increases the plasticized layer from top to the underside and thus the
voids in the welded joint become smaller
-Shoulder diameter effect Shoulder of tool designed to produce heat (due to friction & material deformation) on the surface of the w/pieces
Due to large surface area, friction increases, so amount of heat generated also increase. As the amount increases, the gap on the backside of
welded joint decreases
-Backing plate effect Using backing plate, the gap decreases becoz the use of backing plate was effective utilization of frictional heat for long time resulting in
grain refinement.
Tensile strength increases with the use of backing plate (based on the result)
Conclusion :
-Regression analysis successfully used to develop the relation between input parameters & tensile strength & BHN
-The dominant factors affecting tensile strength is pin length (mm) .With increase in pin length, tensile strength increases
-Use of backing plate decreases gap on the back side of welded plate, increases tensile strength and % yield of welded joint
-Increase in pin length decreases penetration depth on the back side of welded plate and increase BHN
NO
10
2009

AUTHOR
M.B Durdanovic
M.M Mijajlovic
D.S Milcic

TITLE
Heat generation during friction stir welding
process

JOURNAL

D.S Stamenkovic
Objective:
-to explain the process of FSW (5 phases)
-5 main phases : 1)plunging, 2)dwelling, 3)welding, 4)dwelling, 5)pulling out
1st phase : In this paper, w/pieces already previously prepared and there are having technological hole instead of making one during 1st phase
2nd phase: tool remains stay steady relatively to the welding pieces. The mechanical interaction due to the velocity diff between the rotating tool
& the stationary w/piece produces heat by frictional forces. This heat dissipates into surrounding material- welding pieces, T of the material rises
and it softens
3rd phase: moving tool or w/piece relative to each other traversal along the joint line.
4th phase : welding phase traversal stop but tool continue to rotate
5th phase : pulling out the tool
-Explanation of tool that contributed to heat generation
-Conical shoulder helps establishment of the constant P under the shoulder necessary for the welding (also acts as an escape volume for the
material displaced by the probe during the plunge phase
-the probe height is limited by the work piece thickness
Result and discussion
4 phases of heat treatment during welding
Dwelling
Transient heating
Pseudo steady state
Post steady state

NO
11

AUTHOR
TITLE
P. Karthikeyan
Study of relation between welding and hardening
D.Thiagarajan
parameters of FSW Aluminum 2024 alloy
2014
K. Mahadevan
Objective:
-to study the relationship between the welding and hardening parameters of FSW of AL2024 alloy.
Experimental Setup:
-material : AA2024-T3 plates (75mmx50mmx6mm)
-Pin shape : cylindrical threaded tool
-Three diff diameter ratio

JOURNAL

-Exp using 3 factors 3 levels exp design of Box Behnken design of surface methodology
Result and discussion
-Regression models n optimization were done using MINITAB 16 statistical software
-Welding parameter combination has influenced the response that could be clearly seen in the microstructure level of FSW aluminum alloy 2024.
-The proper selection of parameter combination influences the hardening parameters such as hardening exponent, strength coefficient, initial yield
strain which are the main cause for increasing the mechanical property characteristics have been reportedly enhanced
Conclusion
-Tool rotational speed was considered as the most influencing factor for the hardening parameters followed by other welding parameters such as
welding speed and diameter ratio
-The developed regression models are proved viable and reliable in prediction of mechanical property characteristics.
-It was identified that the hardening parameters and welding parameters are well related through this study on FSW of AL2024 alloy
-This relation helped in identifying the behavior of FSW joints anad used to min experimental cost & time

NO
12
2015

AUTHOR
L. Shi
C.S Wu
H.J Liu

TITLE
The effect of the welding parameters and
tool size on the thermal process and tool
torque in reverse dual FSW

JOURNAL
International Journal Of Machine Tools &
Manufacture

Objective:
-to propose the reverse dual rotation FSW as a variant technique
-to develop a numerical model to analyze the heat generation, T distribution,material flow and tool torque for diffrnt welding parameters and tool
size in RDR-FSW
Experimental Setup:
-MATERIAL AL 2024 (500mmx300mmx5mm)
NO
13
2014

AUTHOR
B.T Gibson
D.H Lammein
T.J Prater
W.R Longhurst
etc

TITLE
FSW: Process, automation & control

JOURNAL
Journal Of Manufacturing Processes

Objective :
-to discuss the basic principles of FSW, survey of the latest research and application in the field
Dicussion :
BASIC PRINCIPLES
-Terminology outlined in paper by Threadgills (input variable : rpm,welding speed,plunge depth,tilt angle,sideways tilt angle,shoulder
geometry, shoulder features(scroll), probe geometry & probe features(threads,flute))
-The AS & RS phenomena should be well understood (study of material flow ). Threadgills outline three primary regions & 1 primary
region in the cross section region of FSW joints.

Joint configurations
-square butt joint and lap joint
-Other common joint types (pipe weld,hemispherical welds,multiple lap welds, double T joint welds,corner welds and fillet welds)
Tool design
-many functions of tool (generating heat, promoting mixing,breaking up the joint line,dispersing oxide layers, creating forging pressure,
containing material within joint thereby preventing surface weld flash, preventing the formation(minimizing the impact)of defects such as
wormholes.
-also facilitate a stable force or torque control scheme and be compatible with a range of plunge depths.
-Earliest tool design consisted flat,featureless shoulders and cylindrical developed by Thomas
Materials and tool wear
-primary focus on joining of al,mg & copper
-Primarily machined from tool steels (H13)
-Comprehensive survey of tool material selection relative to workpiece material and welding parameters was compiled by Rai et.al

Defects
-maybe orientation, size or shape.
-excessive flash, excessive concavityvoid wormholes, foreign substance

PROCESS VARIANT
MODELLING
-analytical modelling & numerical modelling (Computational fluid dynamics & FEM)
ROBOTIC MODELLING
-to automate the process for further adoption.Using rotating tool same with milling machine uses end mill.

APPLICATION
-aerospace,private/business aviation

-automobile
-maritime

NO
14

AUTHOR
R.S Mishra
Z.Y. Ma

TITLE
Friction Stir Welding & Processing

JOURNAL
Journal of Materials Sciene and Engineering

2005
Objective :
-to review on the current understanding & development of the FSW and FSP
Discussion
-Process parameters
Tool geometry 2 primary functions : localized heating & material flow(relative size of pin & shoulder important) other feautres not
critical
Welding parameters 2 are very important (tool rotation & welding speed) followed by tilt angle
Joint design most convenient (butt & lap joints)
NO
15

AUTHOR
TITLE
Sabina Luisa Campanelli
Analysis & Comparison of FSW and Laser
Giuseppe Casalino
Assisted FSW of Aluminum Alloy
2013
Caterina Casavola
Vincenzo Moramarco
Objective :
-to study on the FSW of 6mm thick 5754H111 Al alloy
NO
16

AUTHOR
Banglong Fu
Guoliang Qin
2015
Fei Li,
Xiangmeng Meng,
Jianzhong Zhang,
Chuansong Wu
(Fu et al., 2015)
Objective:

TITLE
Friction stir welding process of dissimilar metals
of 6061-T6aluminum alloy to AZ31B magnesium
alloy

JOURNAL

JOURNAL
Journal of Materials Processing Technology

-to study the weld appearance, macro & microstructure & tensile properties of FSW under diff material position, tool offset amount,rotation rate
and tranverse speed
Experimental Setup:
-material : 6061-t6 & AZ31B (200mmx45mmx3mm)
-Tool : H13 Steel
-pin diameter 3.2 mm ,length of pin 2.8mm 10mm diameter of concave shoulder
Result and discussion
-Good mechanical prop achieved when the combination of intermediate speed (600-800rpm) & low tranverse speed (30-60mm/min) by placing
Mg on the advancing side, tool offsetting to Mg 0.3mm.

NO
AUTHOR
TITLE
JOURNAL
17
C.B Jagadeesha
Dissimilar FSW between Al alloy & Mg
Journal of Materials Science & Engineering
2014
(Jagadeesha, 2014)
alloy at low rotational speed.
Objective:
-to investigates the effect of interface offset (IO) varia- tion on the quality and properties of friction stir welded samples and on the magnitude of
thickness of IM layer in the samples and the effect of the thickness of IM layer on the tensile strength of friction stir welded tensile samples
Experimental Setup:
-Material 2024-T3 Al alloy and AZ31B-O Mg alloy. (250mmx80 mmx5 mm)
-AS (2024) & RS (AZ31B)
-Tool material : HDS (threaded pin with top diameter 6mm,bottom diameter 4mm, shoulder d=15mm pin length =4.67mm
Result and discussion
- Successful FSW between 2024-T3 Al alloy and AZ31B-O Mg alloy metal plates of thickness 5mm was carried out in the solid state of the metals
at a rotational speed of 300 rev min-1 and a welding speed of 50mms-1.
- Weld nugget (WN) contains 3 portions, one is a layer of IM at around center of the WN and on either side of the IM layer, equiaxed fine grains
structure of Mg alloy in RS and lamellar like fine grains structure of Al alloy in AS.
NO
18

AUTHOR
J.F Guo
H.C. Chen

TITLE
FSW of dissimilar materials between AA6061
and AA7075 alloys effects of process

JOURNAL
Journal of materials and design

2014

C.N.Sun
G..Bi
(Guo et al., 2014)

parameters

Objective:
-to study the effects of process parameter(material position & welding speed) on the material flow,microstructure,microhardness distribution &
tensile prop of the joints
Experimental Setup:
-Material AA6061 & AA7075. (300mmx50 mmx6.3 mm)
-Shoulder D =15mm,threaded conical probe 5mm at probe base
Result & Discussion
-material mixing much more effective when AA6061 at the AS
-Both materials experience dynamic recrystallization & the grain size in both alloys decreases significantly with the increase of welding speed
NO
19
2004

AUTHOR
Yutaka S Sato
Seung Hwan C. Park
Masato Michiuchi
Hiroyuki Kokawa
(Sato et al., 2004)

TITLE
Constitutional liquation during dissimilar
FSW Of
Mg alloy & Al alloy

JOURNAL

Objective
-to examine microstructural features in dissimilar FSW of Al alloy 1050 and Mg alloy AZ31 & discusses microstructural evolution during FSW
Experimental Setup:
-Material = Al alloy 1050 and Mg alloy AZ31. (300mmx50 mmx6 mm)
-AS (AZ31) & RS (1050)
-Tilt angle : 3 degree, 2450rpm , 1.5mm/s
Result & Discussion
-IMC being produced that contributes to significantly higher hardness in the weld compared to base material
NO
AUTHOR
TITLE
20
Saad Ahmed Khodir
Dissimilar FSW joints between 2024-T3 Al alloy
2007
Toshiya Shibayanagi
&AZ31 Mg alloy
(Khodir & Shibayanagi, 2007)

JOURNAL

Objective
-to investigate the effect of welding speed on microstructure & hardness distribution in dissimilar FSW joints of 2024-T3 & AZ31 Mg alloy
Experimental Setup:
-Material = 2024-T3 & AZ31 Mg alloy (300mmx50 mmx3 mm)
-AS (2024) & RS (AZ31)
-Tool : SKD 61,shoulder D = 12mm & pin D = 4mm (threaded)
-Tilt angle = 3 deg
-rpm=2500min-1, welding speed=200,300,400,550 mm/min
Result & Discussion
-Increasing welding speed lead to redistributed phases in SZ where the region occupied by Al 2024 concentrated in the lower part of SZ while Mg
AZ31B in the upper region beneath the tool shoulder
-SZ comprises 3 regions occupied by Al 2024, Mg AZ31 and irregular structure containing some fragments come from Mg alloy
-Increasing welding speed has a significant influence in the hardness distribution in HAZ & TMAZ
NO
21
2010

AUTHOR
Yan Yong
Zhang Da Tong
Qiu Cheng
Zhang Wen
(Yong et al., 2010)

TITLE
Dissimilar friction stir welding between 5052
aluminum alloy and AZ31 magnesium alloy

JOURNAL

Objective
-to concentrate on the understanding of microstructure evolution and mech prop of the dissimilar FSW between 5052 alloy
Experimental Setup:
-Material = 5052 Al alloy & AZ31 Mg alloy (thickness=6mm)
-AS (5052) & RS (AZ31)
-Tool : concave shoulder d=15mm & cone threaded pin d=6mm , 5mm in length
-Tilt angle = 2
-rpm=600rpm , welding speed=40mm/min

Result & Discussion

-Sound weld between 5052 & AZ31B Mg alloy could be produced through FSW with a rotation speed of 600rpm & welding speed 40mm/min

-microstructure being replaced by equiaxed and fine grain in stir zone. At top of stir zone 5052 & AZ31B were simply bonded.
-microhardness profile presented uneven distribution & the max value of microhardness in the stir zone was twice higher than base materials.
NO
22
2008

AUTHOR
Taiki Morishige
Atsushi Kawaguchi
Masato Tsujikawa
Makoto Hino
Etc
(Morishige et al., 2008)

TITLE
Dissimilar welding of Al & Mg alloys
(A5052 & AZ31B)

JOURNAL

Objective
-to produce dissimilar FSW of Al alloy of A5052-H & extruded AZ31B Mg alloy and discuss the influence of welding parameters on joint
characteristics
Experimental Setup:
-Material = A5052-H & AZ31B (thickness 3mm)
-AS (5052) & RS (AZ31)
-Tool : JIS SKD61 tool steel (shoulder D=12mm, pin D =4mm & length=2.9mm )
-Tilt angle = 3
-rpm=800-1600 min-1 , welding speed=100-400 mm/min
Result & Discussion
-Joint eff reached 61% (not enough to acquire reliable joints but much higher than that of laser welded joints
-highest hardness of each FSW joints has linear relation to heat input ratio
-the reliable FSW of Al & Mg alloy joint that has high joint eff & elongation could acquire ny lower heat input rate to suppress the formation of
Mg17Al12 intermetallic phase
NO
23
2008

AUTHOR
Y.J Kwon
I.Shigematsu
N. Saito
(Kwon et al., 2008)

TITLE
Dissimilar FSW of Mg & Al alloy
(A5052 & AZ31B)

JOURNAL

Objective
-to produce dissimilar FSW of Al alloy of A5052P-0 & AZ31B-0 Mg alloy and investigate the influence of RPM on surface appearance,
microstructure and tensile properties.
Experimental Setup:

-Material = A5052P-0 & AZ31B-0 (30mmX160mmX2mm)

-AS (5052) & RS (AZ31)
-Tool : JIS SKD61 tool steel (shoulder D=10mm, pin D =4mm & length=1.7mm )
-Tilt angle = 3
-rpm=800-1600 rpm , welding speed=300 mm/min
Result & Discussion
-Tool rotation speed of 1000, 1200 & 1400 rpm, detect free weld were successfully obtained.
-Surface morphology of the SZ become smoother with the increasing of tool rotation speed
NO.
24
2009

AUTHOR
Naotsugu Yamamoto
Jinsun Liao
Shuhei Watanabe
Kazuhiro Nakata
(Yamamoto et al., 2009)

TITLE
Effect of Intermetallic Compound Layer on
Tensile Strength
of Dissimilar Friction-Stir Weld of a High
Strength Mg Alloy and Al Alloy
(A5052 & AZ31B Mg alloy)

JOURNAL

Objective
-to produce dissimilar FSW of Al alloy of A5083-0 & AZ31B Mg alloy and investigate the influence of RPM on surface appearance,
microstructure and tensile properties.
Experimental Setup:
-Material = A5083-0 & AZ31B (250mmX74mmX4mm)
-AS (5083) & RS (AZ31)
-Tool : JIS SKD61 tool steel (shoulder D=15mm, pin D =5mm & length=3.9mm )
-Tilt angle = 3
-rpm=300-600 s-1 , welding speed= 40-120 mm/min
Result & Discussion
-Tool rotation speed of 500rpm and welding speed 100mm/min, detect free weld were successfully obtained.
-Higher/lower welding/rotation speed leads to either the formation/defect or lack of bonding in the joints.

NO.
25
2015

AUTHOR
Yong Zhao
Zhenping Lu
Keng Yan
(Zhao et al., 2015)

TITLE
Microstructural characterizations and mechanical
properties in underwater friction stir welding of
aluminum and magnesium dissimilar alloys

JOURNAL

Objective
-to investigate microstructure, distribution of element, hardness and tensile strength & fracture feature of joints.
Experimental Setup:
-Material = A6013 & AZ31B (100mmX90mmX2.5mm)
-AS (A6013) & RS (AZ31)
-Tool : H13 tool steel (shoulder D=16mm, pin D =5mm & length=2.5mm ), threaded cylindrical pin
-Tilt angle = 2.5
-rpm=1200 RPM , welding speed= 80 mm/min
Result & Discussion
-sound welding with good mech prop was produced btween AA6013 & AZ31 Mg alloy with welding speed 80mm/min & rpm 1200
NO.
26
2014

AUTHOR
Alireza Masoudian
Arvin Tahaei
Atefeh Shakiba
Etc.(Masoudian et al.,
2014)

TITLE
Microstructure and mechanical
properties of friction stir weld of
dissimilar AZ31-O magnesium alloy to
6061-T6 aluminum alloy

Objective
-to investigate the microstructure & mech prop of the dissimilar Fsw between AZ31 Mg alloy & 6061 Al alloy.
Experimental Setup:
-Material = A6061-T6 & AZ31-O (t=3mm)
-AS (A6061) & RS (AZ31)
-Tool : H13 tool steel (shoulder D=15mm, pin D =3mm & length=2.9mm ), threaded cylindrical pin
-Tilt angle = 2.5
-rpm=600-1400 RPM , welding speed=20-60 mm/min

JOURNAL

Result & Discussion

-defect free weld between btween AA6013 & AZ31 Mg alloy obtained with welding speed 40mm/min & rpm 1000
-grain refinement occur in SZ due to dynamic recrystallization
NO.
AUTHOR
TITLE
JOURNAL
27
Jiuchun Yan
Microstructure characteristics and performance
Zhiwu Xu
of dissimilar
2005
Zhiyuan Li
welds between magnesium alloy and aluminum
Lei Li
formed by friction stirring
Shiqin Yang
(Yan et al., 2005)
Objective
-to investigate the microstructure & mech prop of the dissimilar Fsw between AZ31 Mg alloy & 1061 Al alloy.
Experimental Setup:
-Material = A1061-T6 & AZ31-O (150mmx40x4mm)
-AS (A1061) & RS (AZ31)
-Tool : high speed steel (shoulder D=20mm, pin D =6mm & length=3.8mm ), threaded cylindrical pin
-Tilt angle = 3
-rpm=200-1000 RPM , welding speed=19-75 mm/min
Result & Discussion
-The welds were formed when the stirring pin was off the centerline to magnesium alloy or to the Al
-when the axis of the pin was just perpendicular to the welding centerline, the brittle intermetallics formed cause the weld to crack.
-The results of XRD indicate that the brittle phases of Al3Mg2 and Al12Mg17 are the cause of the weld cracking.

NO.
1

JOURNAL TITLE
FSW joint of dissimilar materials between AZ31B Mg and 6061 AL alloys :
Microstructure studies & mechanical characterizations (lap joint)

MATERIALS USED
AZ31B & 6061 AL alloys

YEAR
2015

Friction stir welding process of dissimilar metals of 6061-T6 aluminum alloy to AZ31B
magnesium alloy

AZ31B & 6061 AL alloys

2015

Microstructural characterizations and mechanical properties in underwater friction stir

welding of aluminum and magnesium dissimilar alloys

AZ31B & 6013 AL alloys

2015

Dissimilar FSW between Al alloy & Mg alloy at low rotational speed.

AZ31B & 2024 AL alloys

2014

Microstructure and mechanical properties of friction stir weld of dissimilar AZ31-O

magnesium alloy to 6061-T6 aluminum alloy

AZ31B & 6061 AL alloys

2014

Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium
alloy

AZ31B & 5052 AL alloys

2010

Effect of Intermetallic Compound Layer on Tensile Strength of Dissimilar Friction-Stir

Weld of a High Strength Mg Alloy and Al Alloy (A5052 & AZ31B Mg alloy)

AZ31B & 5052 AL alloys

2009

Dissimilar welding of Al & Mg alloys (A5052 & AZ31B)

AZ31B & 5052 AL alloys

2008

Dissimilar FSW of Mg & Al alloy (A5052 & AZ31B)

AZ31B & 5052 AL alloys

2008

10

Dissimilar FSW joints between 2024-T3 Al alloy &AZ31 Mg alloy

AZ31B & 2024 AL alloys

2007

11

Microstructure characteristics and performance of dissimilar welds between

magnesium alloy and aluminum formed by friction stirring

AZ31B & 1061 AL alloys

2005

Fu, B., Qin, G., Li, F., Meng, X., Zhang, J., & Wu, C. (2015). Friction stir welding process of dissimilar metals of 6061-T6 aluminum
alloy to AZ31B magnesium alloy. Journal of Materials Processing Technology, 218, 38-47.
Guo, J., Chen, H., Sun, C., Bi, G., Sun, Z., & Wei, J. (2014). Friction stir welding of dissimilar materials between AA6061 and
AA7075 Al alloys effects of process parameters. Materials & design, 56, 185-192.
Jagadeesha, C. (2014). Dissimilar friction stir welding between aluminum alloy and magnesium alloy at a low rotational speed.
Materials Science and Engineering: A, 616, 55-62.
Kesharwani, R., Panda, S., & Pal, S. (2014). Multi Objective Optimization of Friction Stir Welding Parameters for Joining of Two
Dissimilar Thin Aluminum Sheets. Procedia Materials Science, 6, 178-187.
Khodir, S. A., & Shibayanagi, T. (2007). Dissimilar friction stir welded joints between 2024-T3 aluminum alloy and AZ31 magnesium
alloy. Materials transactions, 48(9), 2501-2505.
Khodir, S. A., & Shibayanagi, T. (2008). Friction stir welding of dissimilar AA2024 and AA7075 aluminum alloys. Materials Science
and Engineering: B, 148(1), 82-87.
Kwon, Y., Shigematsu, I., & Saito, N. (2008). Dissimilar friction stir welding between magnesium and aluminum alloys. Materials
Letters, 62(23), 3827-3829.

Masoudian, A., Tahaei, A., Shakiba, A., Sharifianjazi, F., & Mohandesi, J. A. (2014). Microstructure and mechanical properties of
friction stir weld of dissimilar AZ31-O magnesium alloy to 6061-T6 aluminum alloy. Transactions of Nonferrous Metals
Society of China, 24(5), 1317-1322.
Mohammadi, J., Behnamian, Y., Mostafaei, A., Izadi, H., Saeid, T., Kokabi, A., & Gerlich, A. (2015). Friction stir welding joint of
dissimilar materials between AZ31B magnesium and 6061 aluminum alloys: Microstructure studies and mechanical
characterizations. Materials Characterization.
Morishige, T., Kawaguchi, A., Tsujikawa, M., Hino, M., Hirata, T., & Higashi, K. (2008). Dissimilar welding of Al and Mg alloys by
FSW. Materials transactions, 49(5), 1129-1131.
Sadeesh, P., Kannan, M. V., Rajkumar, V., Avinash, P., Arivazhagan, N., Ramkumar, K. D., & Narayanan, S. (2014). Studies on
friction stir welding of AA 2024 and AA 6061 dissimilar metals. Procedia Engineering, 75, 145-149.
Sato, Y. S., Park, S. H. C., Michiuchi, M., & Kokawa, H. (2004). Constitutional liquation during dissimilar friction stir welding of Al
and Mg alloys. Scripta Materialia, 50(9), 1233-1236.
Yamamoto, N., Liao, J., Watanabe, S., & Nakata, K. (2009). Effect of intermetallic compound layer on tensile strength of dissimilar
friction-stir weld of a high strength Mg alloy and Al alloy. Materials transactions, 50(12), 2833-2838.
Yan, J., Xu, Z., Li, Z., Li, L., & Yang, S. (2005). Microstructure characteristics and performance of dissimilar welds between
magnesium alloy and aluminum formed by friction stirring. Scripta Materialia, 53(5), 585-589.
Yong, Y., Zhang, D.-T., Cheng, Q., & Zhang, W. (2010). Dissimilar friction stir welding between 5052 aluminum alloy and AZ31
magnesium alloy. Transactions of Nonferrous Metals Society of China, 20, s619-s623.
Zhao, Y., Lu, Z., Yan, K., & Huang, L. (2015). Microstructural characterizations and mechanical properties in underwater friction stir
welding of aluminum and magnesium dissimilar alloys. Materials & design, 65, 675-681.