gap chart of fsw

Sr. No.AuthorDate of PublishExperiment doneTools and Materials usedConclusionGap

1.L. Karthikeyan, V.S. Senthil Kumar(Engg. Guindly Campus, Anna university, Chennai)Received:23/08/2010

Accepted:22/12/2010

Available online:05/01/2011Effect of process variables:1.Axial Force2.Tool Feed3.Rotational Speedon the properties:1.Yield Strength2.Ductility3.Ultimate Tensile Strength4.Micro Hardness were studied, and surface defects were also analyzed under these parameters.w/p Material: AA6063-T6 Aluminium Alloy

Tool: Hub dia: 18Tip dia: 6Tool tip height: 5.7RH Thread Pitch 1mm

Workpiece:200x50x10

Machine used:Spl prps FSW m/cPmax=30 hpFmax(axial)=25 kNNmax=3000 rpm

Testing Setup:UTM, Vickers microharness tester with load 0.5 Kgf and dwell period 15s

Tensile specimen:ASTM B308

Etchant used:Kellers reagent & 0.5% hydrofluoric acid

Study Tools:SPSS 17.0, Regression Analysis1. Enhanced mechanical propertiesachieved with a tool feed of 40.2 mm/min, toolrotational speeds in the range of 1200-1400 rpmand axial force of 10 kN.

2. The maximum increase in the ultimatetensile strength was 46.5%, ductility was 133% and microhardnesswas 33.4% in relation to the parent material.

3. All the specimens processed with axial force of 8kN yielded process defects.

4. Mathematical model developed using regression analysis.(i) 9% deviation from process variables yield, tensile strengths and Vickers microhardness.

(ii) 12% deviation from ductility.

2.Hidetoshi Fujii, Ling Cui, Masakatsu Maeda, Kiyoshi Nagi(Joining and Welding Research Institute, Osaka University, Japan)Accepted:18/11/2005Effect of tool shape on mechanical properties and microstructure of FSW aluminium alloys.w/p material:1050-H24 (soft alloy), 5083-O (hard alloy), 6061-T6 (relatively soft alloy)

w/p dimensions:300x70x5

Tool:1.simple tool:Shoulder dia: 15Shoulder concavity: 10oTip dia: 6Tool tip height: 4.7Tilt angle: 3o2. Ordinary tool with threads:RH Thread Pitch 0.5mm (opposite to direction of rotation)3.Tool with triangular prism probe:Circumsbscribed dia: 6mm

Machine:Plunge depth controlled FSW machine

Testing Setup:Optical microscopy,Two K-type thermocouple (9mm from centre), orientation image microscopy

Etchant used:Kellers reagent1. Columnar tool without threads is suitable for soft materials.

2. For 6061-T6, tool shape has almost no effect on microstructure and mechanical properties.

3. For hard alloys, tool shape is decided by rotation speed:(i) at lower speeds(600 rpm)-No effect.(ii) at medium speeds (800 rpm)- threaded column is best.(iii) at fast speed (1500 rpm)- triangular prism tool is best.

4. Mechanical properties at 600 rpm are best and defect free macrostructure was obtained.

5. Temperature at tool base and top surface decreases with the tool feed.

6. Temperature at bottom surface is low for the triangular tool due to low contact area.(i) No exact reasons for the low strengths for other tool shapes were given. He just said that it is due to the formation of more cracks on surface.

3.H. Bisadi, A. Tavakoli, M. Tour Sangsaraki(Iran university of Science & technology, Tehran, Iran.& Islamic Azad university, Tehran, Iran)Received:13/04/2012

Accepted:16/06/2012

Available online:28/06/2012Study of Rotational & Welding speeds on microstructure and mechanical properties of aluminium alloy and commercially pure copper sheet lap joints.

w/p material:1. Al50832. commercially pure Cu sheet.

w/p dimensions:Al: 150x100x2.5Cu: 150x100x3

Tool material:H13 quenched and tempered tool

Tool dimensions:Shoulder dia 23Tool tip dia 5Tip height: 3.8Tool tilt angle: 3.5Shoulder penetration: 0.4 mm

4.S. Malarvizhi, V. Balasubramanian(Centre for Materials Joining & Research, Annamalai University, Tamil Nadu, India.)Received:23/01/2012

Accepted:02/04/2012

Available online:12/04/2012Influences of tool shoulder diameter to plate thickness ratio on stir zone formation and tensile properties of dissimilar joints.w/p Material:AA6061 aluminium-AZ31B magnesium alloys.

w/p dimensions:200*500*6 each (rolled)Al: retreating sideMg: advancing Side.

Tool material:High speed steel

Tool dimensions:Probe dia: 6Height: 5.7Shoulder dia: 12-24 (2-4 times of plate thickness)

Testing Setup:Eletromechanical controlled UTM and Light Optical Microscope.1. Joint fabricated with a tool shoulder dia of 21 mm (3.5 times the plate thickness) yielded maximum tensile strength of 192 MPa.1. Magnesim advancing and aluminium retreating.

5.R. Palanivel, P.Koshy Mathews, N.Murugan, I.Dinaharan(Coimbatore Tamilnadu)Received:14/01/2012

Accepted:16/03/2012

Available online:23/03/2012Effect of tool rotational speed and pin profile on microstructure and tensile strength of dissimilar FSWw/p material:AA5083-H111 (retreating) & AA6351-T6 (advancing) aluminium alloys

w/p dimensions:100*50*6 (rolled)

Tool types:1. Straight square2. straight hexagon3. straight octagon4. tapered square5. tapered octagon

Tool rotation speeds:600 rpm, 950 rpm, 1300 rpm1. Out of unmixed region, mechanically mixed region and mixed flow region, rotation speed & pin profile influenced the formation of mixed flow region.2. Tapered tools and at 600 rpm, no mixed flow region was obtained.3. straight square pin and at 950 rpm, highest strength of 273Mpa was observed.4. Variation in tensile strength is due to material flow behaviour, loss of cold work in the HAZ of AA5083 and overaging of precipitates of AA6351 and defects in weld zone.5. Tapered tools caused tunnel defect at the bottom of the joints.(i) FSW in different rolling directions.

6.Weifeng Xu, Jinhe Liu, Hongqiang Zhu, Li FuReceived:19/10/2012

Accepted:26/12/2012

Available online:03/01/2013Influence of welding parameters and tool pin profile on microstructure and mechanical properties along the thickness in a FSW aluminium alloyw/p material:2219-T62 Al alloy

w/p dimensions:400*100*12mm thick rolled plate (welding // to rolling direction)

Tool material:H13 steel

Tool types1. threaded and tapered with three spiral flutes2. threaded and tapered with triangle

Tool dimensions:Shoulder dia: 26Probe height: 11.7Threaded pin of dia 11.8 (root), 5.9 (head)Tilt angle: 2.5o

Rotational speeds:300, 400 & 500rpm

Traverse speeds:60, 80 & 100mm/min

1. Larger grain sizes were observed in top section, smaller in bottom.2. size of grains decreased and distribution of second-phase particles were more diffuse at N=300 than 500rpm.3. Grain size was finer for the three spiral flute tool4. strength and ductility of top is slightly higher for first tool and increases with traverse speed or decrease of rotational speed.5. tensile fracture occur at 45o (in Nugget) & brittle normal to stress axis (in HAZ)

7.B. Ashok Kumar, N. Murugan

TamilNaduReceived:11/10/2013

Accepted:22/12/2013

Available online:08/01/2014Influence of welding parameters on AA6061-T6AlN (aluminium nitride) compositeAMC (aluminium matrix composites)w/p material:AA6061-T6/AINp


Tool material:High carbon high chromium steel (HCHCr), oil hardened to 60-62 HRC

Tool dimensions:Square tool:

Regression models, and optimization techniques were used to test results.

8.Mohsen Baharami, Mohd. Kazem Besharati.

Tehran, IranReceived:13/04/2013

Accepted:14/07/2013

Available online:24/07/2013Role of pin geometry in microstructure and mechanical properties of AA7075 aluminium alloy with SiC injection.w/p material:AA7075/SiC nano composite

w/p dimensions:100x60x6mm thick

Tool material:H13, heat treated to 58HRC

tool types:1. threaded tapered(TT)2. triangular(T)3. square(S)4. four flute square (FS)5. four flute cylindrical(FC)

Tool dimensions:Circumscribed circle: 6mmPin Depth: 5.7 mm

profile formation:width: 0.2mmdepth: 5mm

Parameters:RPM: 1250Speed: 40mm/min1.TT distribute SiC most uniformly, whereas FC least.2. Highest UTS was obtained with T tool, whereas FC lowest.3. All but FC tool made specimen fractured from the base metal.4. FC tool showed highest harness of 124HV.Check fixture pic

9.Mohsen Baharami, Mohd. Kazem Besharati.

Tehran, IranReceived:22/02/2013

Accepted:02/07/2013

Available online:12/07/2013Investigate the effect of SiC nanoparticles on mechanical properties of FSW joints at different rotational and travelling speeds.w/p material:AA7075/SiC nano composite


Tool material:H13, heat treated to 58HRC

tool dimensions:threaded taper pin tool: shoulder dia: 16mmtip height: 5.7mm

profile formation:width: 0.2mmdepth: 5mm

parameters: N=800, 1000, 1250 rpmTravelling speed:30.5, 40, 50 mm/min1. high powder dispersion at 1250 rpm2. SiC nanoparticles refined microstructure by impeding recrystallized grain growth, multiplying grain growth, multiplying nucleation sites.3. UTS at 1250 rpm 40mm/min was 31% superior than without SiC.4. 76.1% more elongation with SiC

10.Chase D. Cox, Brian T. Gibson, David R. DeLapp

Nashville, U.S.Received:01/08/2013

Accepted:08/10/2013

Available online:10/10/2013A method for double sided firction stir spot welding (FSSW)w/p material:AA6061 plate

w/p thickness:1mm & 2mm

Tool type:Rotation anvil & pin less shouldered tool1. significantly reduce the axial forces experienced by weld machine2. stronger spot welds than traditional FSSW

11.J.F. Guo, H.C. Chen, C.N. Sun, G. Bi, Z. Sun, J. Wei

SingaporeReceived:12/08/2013

Accepted:29/10/2013

Available online:09/11/2013FSW of dissimilar materials & effects of process parametersw/p material:AA6061 & AA7075

w/p dimensions:300x50x6.3mm thick

Tool dimensions:Threaded conical probe with three flatsShoulder dia: 15mmProbe dia: 5mm

Parameters:N=1200rpm

1. mixing is effective with AA6061 on advancing side.2. grain size of 7075 is smaller.3. grain size decreases with increasing speed4.All joints failed at HAZ of 6061 where minimum hardness, and good ductility was located.5. UTS of joints increases with decrease in heat inputMetals of AA6xxx & AA7xxx series

12.Yashar Javadi, Seyedali sadeghi

Semnan, IranReceived:29/07/2013

Accepted:08/10/2013

Available online:17/10/2013Taguchi optimization and Ultrasonic measurement of residual stresses in FSW

Hole drilling method was used for measurementw/p material:AA5086 al

w/p dimensions:150x100x8mm

tool material:H13, pin height=7.8mm

Process parameters:N=400, 800rpmV=12, 100 mm/mind= 6, 8 mmD= 20, 24 mm1. Pead residual stress occur on advancing side.2. Most significant effect on RS is of feed rate.3. then of rotational speed.4. d & D has no effect on residual stresses.Effect of force is not considered.

*Also effect of w/p material and clamping force may be calculated.

13.Bo Li, Zhenhua Zhang, Yifu Shen, Weiye Hu, Lei Luo

Nanjing, PR ChinaReceived:26/05/2013

Accepted:07/07/2013

Available online:18/07/2013Dissimilar FSW on Al & Ti alloy employing a modified butt joint configuration: influence of process variables on the weld interfaces and tensile properties.w/p material:Ti-6Al-4V & Al-6Mg

Tool material:WC-13 wt.% Co matrix material1. tensile strength of the joint reach 92% of the parent material.2. defects were negligible.Geometry can be employed to other materials too.

14.Xun Liu, Shuhuai Lan, Jun Ni

Ann Arbor, MI, USAReceived:22/10/2013

Accepted:01/02/2014

Available online:07/02/2014Dissimilar FSW of Aluminium alloy & advanced high strength steelw/p material:AA6061-T6, TRIP (transformation induced plasticity) 780/800 steel

w/p dimensions:tsteel= 1.4mm thick,tal=1.5 mm thick

tool:conically tapered tool

tool dimensions:shoulder dia: 12.7mmtip dia: 3.91mmtip height: 1.2 mmangle: 20o with axis

tool material:Tungsten carbide with 10% cobalt1. Maximum tensile strength obtained is 85% of Al alloy.2. Intermetallic compound layer (IMC) of FeAl & Fe3Al with thickness of less than 1 m was formed at Al-Fe interface in advancing side, which contribute to joint strength.3. welding speed has negligible effect on IMC formation.4. under low N & small tool offset, FeAl was formed.Dislocation motion at nugget.

15.N. Mendes, A. Loureiro, C. Martins, P. Neto, J.N. Pires

Coimbra, PortugalReceived:17/12/2013

Accepted:13/02/2014

Available online:20/02/2014Effect of FSW parameters on Acrylonitrile butadiene Styrene (ABS) plate weldsw/p material:ABS

w/p dimensions:300x80x6mm

Tool type:Conical threaded tool

Tool dimensions:Tool length: 5.9mmdbase=10mmdtip=6mm

Parameters:N=1000-1500 rpmv=50-200 mm/min Faxial=.75-4 KN1. If N>1250 & F>1.5 => no defects.2. Axial force contributes to material mixing and prevents formation of cavities in retreating side.3. High N & high F => high strength efficiency.4. (R/v)>10 lead to good weld crown appearance.

16.Mehdi Pirizadeh, Taher Azdast, Samrand Rash Ahmadi

Urmia, IranReceived:03/05/2013

Accepted:15/08/2013

Available online:25/08/2013FSW of thermoplastic using a newly designed toolw/p material:ABS (Acrylonitrile Butadiene Styrene) sheets

w/p dimensions:100x80x5 mm sheets

Tool material:304 steel T300 series

FSW Parameters:Shape of pin: simple & convexN= 400, 600, 800 rpmV= 20, 40, 60 mm/min1. Root defect and back slit was eliminated2. Tensile strength decreases with increase in rotational speed.3.Both low and high traverse speed decreases heat generation => low tensile strength.4. Convex pin had large TS than simple pin

17.Pooya Pourahmad, Mehrdad Abbasi

Islamic Azad university, Karaj, IranReceived:09/05/2012

Accepted:20/09/2012

Dissimilar FSW of Al6013 & Mg& study of material flow and phase transformations w/p materials:Al6013 & Mg


Tool:H13 steel heat treated to 900oC for 1 hr & quenched in oil.

Tool dimensions:Conical ToolD= 20mmd1= 6mmd2= 4mmh= 6mm

Parameters:N=800-2000 rpmV= 31-75 mm/minTilt angle= 2 & 3oOffset: -1, 0, 1 mm1. Defect free welding when N=1600rpm, v=35mm/min, angle = 3o and tool 1mm offset towards Al2.From X-ray, it was observed that, displacement of the implanted steel was bigger in advancing side.3. In upper layer, Al3Mg2 or beta layer formed due to high temperature & extrusion effect of Shoulder.4. Thickness of Al3Mg2 was 4um & 12um after 1 h & 2 h of heating respectively. After 4 hr, Al12Mg17 23um thick was formed.5. Tensile strength was increased after 1 hr of heat treatment.Pre & Post heating effect can be analyzed

18.Tracie PraterReceived:03/12/2012

Accepted:10/07/2013

Available online:02/08/2013FSW of metal matrix composites (MMCs) & analyzation of tool wear.w/p material:Al359/SiC/20p

w/p size:.635 cm

Tool material:Tungsten carbide, HSS, Hardened Steel tool with diamond coating

19.H.M. Rao, R.I. Rodriguez, J.B. Jordon

Tuscaloosa, USAReceived:28/08/2013

Accepted:16/12/2013

Available online:19/12/2013FSSW of rare-earth containing ZEK100 magnesium alloy sheets (Lap joint), and influence of effective sheet thickness, interfacial hook width, shoulder plunge depth.w/p material:rare-earth containing ZEK100 mg alloy sheets

w/p dimensions:1.4 mm thick

Tool type:Cylindrical unthreaded tool

Tool material:H13

Tool dimensions:D=12mmd=5mmH=1.8mm1. Increase in N decreases hardness2. Coupons with large effective upper sheet thickness had highest lap shear strength.3. 1500 rpm and 0.2 mm plunge depth gave highest lap shear strength.4. Large effective sheet thickness => interfacial shear failure.5. small effective sheet thickness => Nugget pullout failure.Effect of V & F tool geometry, not observed.

20.Emad Salari, Mohammad Jahazi

Tehran, Iran&Montreal, CanadaReceived:30/08/2013

Accepted:06/02/2014

Available online:13/02/2014Influence of Tool geometry, N on FSLW (friction stir lap welding) of 5456 aluminium alloy sheets.w/p material:AA5456 aluminium alloy with two different tempers: T321 & O

w/p dimensionst=5, 2.5mm

Tool types:1. Conical thread pin (CTP)2. cylindrical conical thread pin (CCTP)3. stepped conical thread pin (SCTP)4.Flared Triflute pin (FTP)

Parameters:N= 600, 800rpm

1. Highest Joint performance was obtained with SCTP2. Reason for above point is higher contact surface and better plasticity of material due to its threads and steps.3. Joint with 600 rpm gave better tensile properties, irrespective of the tool shape.4. Hook defect height & effective lower plate thickness were used as a quality criterian for welded joints.

21.Hyung-Seop Shin

Andong Kyungbuk, Republic of KoreaAvailable online:20/12/2012Dissimilar Friction stir spot welding of Bulk metallic glass & light weight alloys.Effect of Tool geometry.w/p material:BMG (Zr41.5Ti13.8Cu12.5Ni10Be22.5) with Al alloy (A5052-H32), and Mg alloy (AZ31B)

w/p dimensions:BMG: 10x80x1Al & Mg: 15x100x1

Tool dimensions:D= 6mmd=2.5mm (circumsubscribed in case of tt)h=1.1mm

Tool types:Triangular & cylindrical

Parameters:Plunge speed: 6mm/minPlunge depths: 1.8, 1.9 & 2mm N=2700rpm1. In case of triangular pin tool, its sharp edge produced much more chips due to dominant cutting effect rather than stirring effect, which lowers the vertical load & temperature.2. Effect of tool geometry on failure load only existed at smaller tool plunge depth.3. The above effect was dominant in case of BMG-Mg alloy.BMG & Ni based alloy.

22.Y.F. Sun, J.M. Shen, Y. Morisada, H. Fujii

Osaka University, Ibaraki, JapanReceived:25/06/2013

Accepted:20/08/2013

Available online:27/08/2013FSSW of Low carbon steel, preheated by high frequency induction(Lap joints)w/p material:S12C low carbon steel

w/p dimensions:100x30x1.6mm thick

tool material:WC-Co based tool

Tool dimensions:D= 12mm (concave)d= 4mmh=1.9mm (unthreaded)

Parameters:N=800rpm,F=2500kg

1. Grain size increased due to preheating due to slow cooling rate after welding 2. TMAZ with preheating contains a low fraction of low angle boundary.3. With preheating, load and shear load carrying capacity gets increased.Temperature variation can be done.

23.Long Wan, Yongxian Huang

Harbin, Peoples Republic of chinaReceived:13/07/2013

Accepted:29/09/2013

Available online:10/10/2013Self Support Friction Stir Welding( SSFSW) of Aluminium alloy & study of microstructure & microhardnessw/p material:Al6082-T6


Parameters:N=800rpmTilt angle= 4oPlunge depth= 0.1mm

Tool material:HSS

Tool type:Self support tool made of two shoulders (upper concave & lower convex)

1. weld shape made was slightly hour glass shaped. All four zones presented in joint due to introduction of lower shoulder.2. Av. microhardness in WNZ near TMAZ was lowest due to overaging & coarser second phase particles3. TMAZ experienced both temperature and deformation during FSW & form highly deformed structure.4. Grain size decreases with increasing distance from the weld centreline in HAZ, But grain structure didnt alter.1.Lower concave surface shoulder2. Other parameters could be checked using this tool

24.Yong Zhao, Lilong Zhou, Qingzhao Wang, Keng Yan, Jiasheng Zou

Jiangsu, ChinaReceived:29/08/2013

Accepted:09/12/2013

Available online:16/12/2013FSW of 6013 Al alloy (T-Lap & T-Butt-Lap Joints), and analyzing defects & tensile properties of coupons. w/p material:6013-T4

w/p dimensions:210x110x2.5

Tool material:H15

Tool type:Concave shoulder conical unthreaded tool

Tool dimensions:

Parameters:N=1000rpmV= 100, 200, 300, 400 mm/minFillet radius= 2mm, 3mm1. No tunnel defect obtained with v=100mm/minArea of tunnel defect increases with V2. Kissing defects are found at double corners of T-Joint3. Highest tensile strength found in T-Butt-Lap Joint at v=200mm/min 3. Kissing bond area is characterized with brittle fracture, whereas, metallic bonding area near top surface is marked by ductile fracture.4.In shins tensile failure was due to kissing defect whereas, in stringer, it is due to tunnel defect.

25.D. Trimble, J. Monaghan, G.E. ODonnell

Dublin, Ireland----------------Force generation during FSW of AA2024-T3, through rotating component dynamometer & with FEMw/p material:AA2024-T3


Tool material:H13 steel tool

Tool types:1. threaded cylindrical2. smooth cylindrical

Tool dimensions:D=18mm (concave with 7o recess angle)d= 6.5mmh=4.6mm

Parameters:N=450 rpmV=90, 180mm/minTilt angle=2o

1. Max. forces occur during plunge stage, and reduce significantly (35%) during the translational stage.2. During plunging damage to tool pin may occur & during translation damage to shoulder is more likely to occur.3. threaded tool increase intimate mixing & material deformation. Therefore lower max. vertical & welding forces, higher weld strength & elongation were recorded for it.

26.L. Ceschini, I. Boromei, G. Minak

Bologna, ItalyReceived:17/07/2006

Accepted:29/07/2006

Available online:17/10/2006Effect of FSW on microstructure, tensile & fatigue properties of AA7005 aluminium compositew/p material:AA7005/10pAl2O3p


Tool material:Ferro-Titanit

Tool dimensions:D=18mmd= 8mmh=6.8mmleft hand screw with 1.25 pitch

Parameters:F=12kNN=600rpmV=300rpm

1. Abrasive effect of tool reduce particle sizes but didnt alter particle shape. Grain refinement was observed.2. Hardness slightly increased in TMAZ, but was comparable in nugget zone.3. Low cycle fatigue life gets decreased.

27.Vijay Soundrarajan, Srdja Zekovic

Richardson, USAReceived:05/01/2005

Accepted:15/02/2005

Available online:21/04/2005Thermo-mechanical model with adaptive boundary conditions for FSW of Al6061w/p material:6061-T6


Tool material:CPM 1V

Tool dimensions:Shank dia: 19mmD= 24mmd= 5.2mm

1. Residual stresses are determined in w/p after welding, dominant part of which are thermal stresses.2.w/p surface temperature right under the tool reaches very close to the solidus temperature during FEM thermal analysis.

28.M. Jariyaboon, A.J. Davenport, R. Ambat, B.J. Connolly

Birmingham, U.K.Lynby, DenmarkBristol, U.K.Cranfield, U.K.Received:12/01/2006

Accepted:23/05/2006

Available online:05/09/2005Effect of welding parameters on corrosion behaviour of FSWw/p material:AA2024-T351

w/p dimensions:25x10x6.35 mm

tool type:M8 thread tool

Parameters:N=215, 350, 468 rpmV=75, 95, 154mm/min1. rotation speed is main parameter for location of welds.2. for low N, corrosion corrosion attack is in nugget zone due to significant increase in anodic reactivity.3. At higher N, corrosion attack is in HAZ region due to presence of sensitized grain boundaries. Nugget shows cathodic reactivity which protects region from attack.Corrosion due to other parameters, such as temperature, force, ground formation.

29.

gap chart of fsw

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