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Friction stir welding has been successfully developed for many non-ferrous alloys, and its feasibility for steel has been demonstrated. The process is fully mechanised, needs no traditional welder skills, no consumables, and produces solid state welds with minimal distortion, and excellent mechanical properties. It is also very useful for joining dissimilar materials.
In friction stir welding (FSW) a cylindrical, shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two pieces of sheet or plate material, which are butted together. The parts have to be clamped onto a backing bar in a manner that prevents the abutting joint faces from being forced apart. Frictional heat is generated between the wear resistant welding tool and the material of the workpieces. This heat causes the latter to soften without reaching the melting point and allows traversing of the tool along the weld line. The plasticised material is transferred from the leading edge of the tool to the trailing edge of the tool probe and is forged by the intimate contact of the tool shoulder and the pin profile. It leaves a solid phase bond between the two pieces. The process can be regarded as a solid phase keyhole welding technique since a hole to accommodate the probe is generated, then filled during the welding sequence.
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