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Friction stir welding is a relatively new technique for welding. It is a process that requires few tools and materials, while still producing strong, sound welds in a variety of metals. Friction stir welding is an advanced process which utilises a non-consumable, rotating tool that is pressed against the metal being welded. The heat generated by friction between the tool and the metal causes the metal to soften, allowing the tool to rotate and stir the softened metal, creating a strong, sound weld.

Friction stir welding has opened up a range of new applications. It is being used in the aerospace, automotive, marine and structural engineering sectors. Its use is primarily for aluminium alloys, but it is increasingly being used on certain steel, copper and titanium alloys too.

Friction stir welding offers numerous advantages over other welding techniques. For example, it is a smooth, clean process that produces few sparks and smoke, and no spatter. It is also fast and efficient, requiring significantly less preparation time for a weld than traditional processes such as arc and gas welding. It is also accurate and produces very high quality welds with excellent mechanical properties, such as strength, fatigue life and corrosion resistance.

The working principle of friction stir welding is simple yet elegant. The tool is a cylindrical pin, usually made of tungsten carbide. It is held against the metals to be joined and rotates at high speed while it is pressed against them. This causes friction between the tool and the metal, generating heat, which softens the metal. The tool then penetrates into the softened metal and stirs the metal, creating a strong bond between the two pieces. The tool is then retracted, leaving only a small hole at the weld interface.

One of the key factors in producing a good weld using friction stir welding is the correct selection of the tool and tool material. The tool should be chosen based on the material being welded, the size and shape of the joint, as well as the welding speed and pressure applied. Different tool materials such as tungsten carbide, carbide alloys and titanium alloys are available for different applications.

Friction stir welding is a relatively new process, but it has quickly gained acceptance in a number of industries. Its advantages make it well suited to a range of applications and it is being used increasingly often, replacing traditional welding techniques wherever it can.

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