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Original Articles

Design and Optimization of Friction Stir Welding Tool

, , &
Pages 1199-1205 | Received 15 Sep 2009, Accepted 20 Nov 2009, Published online: 17 Dec 2010

Keep up to date with the latest research on this topic with citation updates for this article.

Read on this site (19)

Yash Dugar, Nishant Singh, Ajit Kumar, Gowtham Vinayagamurthy, S. P. Shanmuganatan & Madhusudan Manjunath. (2023) Microstructural studies and parametric optimization of dissimilar friction stir welds. Welding International 37:4, pages 206-225.
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Pragyan Paramita Mohanty. (2022) Wear of friction stir tools considering qualitative and quantitative aspects: a review. International Journal of Ambient Energy 43:1, pages 5535-5553.
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Dipen Kumar Rajak, Durgesh D. Pagar, Pradeep L. Menezes & Arameh Eyvazian. (2020) Friction-based welding processes: friction welding and friction stir welding. Journal of Adhesion Science and Technology 34:24, pages 2613-2637.
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R. Ramesh Kumar, R. Varatharajan & V. Thiruvengadam. (2020) An investigation of friction welding heat dissipation in titanium alloy and stainless steel. International Journal of Ambient Energy 41:14, pages 1639-1644.
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Dhanesh G. Mohan & S. Gopi. (2020) Induction assisted friction stir welding: a review. Australian Journal of Mechanical Engineering 18:1, pages 119-123.
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V. K. Parikh, A. D. Badgujar & N. D. Ghetiya. (2019) Joining of metal matrix composites using friction stir welding: a review. Materials and Manufacturing Processes 34:2, pages 123-146.
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Md. Reza-E-Rabby & Anthony P. Reynolds. (2018) Some effects of tool geometric features on friction stir weld response parameters. Science and Technology of Welding and Joining 23:7, pages 575-584.
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Nidhi Sharma, Arshad Noor Siddiquee, Zahid A. Khan & Mohsin T. Mohammed. (2018) Material stirring during FSW of Al–Cu: Effect of pin profile. Materials and Manufacturing Processes 33:7, pages 786-794.
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Md. Reza-E-Rabby, Wei Tang & Anthony P. Reynolds. (2018) Effects of thread interruptions on tool pins in friction stir welding of AA6061. Science and Technology of Welding and Joining 23:2, pages 114-124.
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R. Adalarasan & A. Shanmuga Sundaram. (2016) Study of friction welding characteristics of Al/SiC composite and application of grey-based TOPSIS. Journal of the Chinese Institute of Engineers 39:4, pages 484-492.
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Hamid Montazerolghaem, Alireza Fadaie Tehrani & Mohsen Badrossamay. (2014) An Innovative Approach for Manufacturing of Thin Welded Blanks and Coils. Materials and Manufacturing Processes 29:8, pages 889-893.
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CemC. Tutum, Kalyanmoy Deb & JesperH. Hattel. (2013) Multi-Criteria Optimization in Friction Stir Welding Using a Thermal Model with Prescribed Material Flow. Materials and Manufacturing Processes 28:7, pages 816-822.
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M. Selvaraj, Vela Murali & S.R. Koteswara Rao. (2013) Mechanism of Weld Formation during Friction Stir Welding of Aluminum Alloy. Materials and Manufacturing Processes 28:5, pages 595-600.
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Adel Mahmood Hassan, Mohammed Almomani, Tarek Qasim & Ahmed Ghaithan. (2012) Effect of Processing Parameters on Friction Stir Welded Aluminum Matrix Composites Wear Behavior. Materials and Manufacturing Processes 27:12, pages 1419-1423.
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A. Kumar & L. Suvarna Raju. (2012) Influence of Tool Pin Profiles on Friction Stir Welding of Copper. Materials and Manufacturing Processes 27:12, pages 1414-1418.
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A. Esmaeili, M.K. Besharati Givi & H.R. Zareie Rajani. (2012) Experimental Investigation of Material Flow and Welding Defects in Friction Stir Welding of Aluminum to Brass. Materials and Manufacturing Processes 27:12, pages 1402-1408.
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A Esmaeili, M K Besharati Givi & H R Zareie Rajani. (2012) Investigation of weld defects in dissimilar friction stir welding of aluminium to brass by radiography. Science and Technology of Welding and Joining 17:7, pages 539-543.
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Y N Zhang, X Cao, S Larose & P Wanjara. (2012) Review of tools for friction stir welding and processing. Canadian Metallurgical Quarterly 51:3, pages 250-261.
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Articles from other publishers (49)

Avinish Tiwari, Pardeep Pankaj, Pankaj Biswas & Arvind Kumar. (2023) Characterization of ultrafine grain tungsten carbide tool and its wear investigation in friction stir welding of HSLA steel. Tribology International 186, pages 108579.
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Amit Muchhadiya, Soni Kumari, Din Bandhu, Kumar Abhishek & Jay J. Vora. (2023) Elucidating the Effect of Friction Stir Welding Variables on HDPE Sheets Using Grey Integrated with Fuzzy: Experimental Investigation and Parametric Optimization. JOM 75:7, pages 2684-2692.
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M. Boukraa, T. Chekifi & N. Lebaal. (2022) Friction Stir Welding of Aluminum Using a Multi-Objective Optimization Approach Based on Both Taguchi Method and Grey Relational Analysis. Experimental Techniques 47:3, pages 603-617.
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Francisco B. Ferreira, Igor Felice, Isaque Brito, João Pedro Oliveira & Telmo Santos. (2023) A Review of Orbital Friction Stir Welding. Metals 13:6, pages 1055.
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Bala Murali Nagarajan & Manikandan Manoharan. (2021) Assessment of dissimilar joining between metal and polymer hybrid structure with different joining processes. Journal of Thermoplastic Composite Materials 36:5, pages 2169-2211.
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Tahar Madani, Moustafa Boukraa, Mouloud Aissani, Tawfiq Chekifi, Abdelkader Ziadi & Mounir Zirari. (2023) Experimental investigation and numerical analysis using Taguchi and ANOVA methods for underwater friction stir welding of aluminium alloy 2017 process improvement. International Journal of Pressure Vessels and Piping 201, pages 104879.
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Surendra Kumar Lader, Mayuri Baruah, Raj Ballav & Swarup Bag. (2023) Recent Developments in Friction Stir Welding Tools for Weld Bead Defects Minimization – A Review. Soldagem & Inspeção 28.
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Sachindra Shankar, Kush P. Mehta, Somnath Chattopadhyaya & Pedro Vilaça. (2022) Dissimilar friction stir welding of Al to non-Al metallic materials: An overview. Materials Chemistry and Physics 288, pages 126371.
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Renangi Sandeep & Arivazhagan Natarajan. (2022) Advances in joining technologies for the innovation of 21 st century lightweight aluminium-CFRP hybrid structures . Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 236:3, pages 1239-1255.
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Kia Wai Liew, Yu Zorn Chung, Guo Sheng Teo & Chee Kuang Kok. (2021) Effect of Tool Pin Geometry on the Microhardness and Surface Roughness of Friction Stir Processed Recycled AA 6063. Metals 11:11, pages 1695.
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Sehan Naik, Siddharth Panda, Sarvesh Padhye, Greig Lobo, Girish Joshi, Samadhan Deshmukh & Asha Ingle. (2021) Parametric review on friction stir welding for under water and dissimilar metal joining applications. Materials Today: Proceedings 47, pages 3117-3122.
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Renangi Sandeep & N. Arivazhagan. (2021) Innovation of thermoplastic polymers and metals hybrid structure using friction stir welding technique: challenges and future perspectives. Journal of the Brazilian Society of Mechanical Sciences and Engineering 43:1.
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Sara Bocchi, Gianluca D’Urso & Claudio Giardini. (2021) The effect of heat generated on mechanical properties of friction stir welded aluminum alloys. The International Journal of Advanced Manufacturing Technology 112:5-6, pages 1513-1528.
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Murat Konar, Salim Aslanlar, Erdinç İlhan, Melih Kekik, Görkem Özçelik, Mehmet Buğra Güner, Arif Fatih Yiğit & Tolga Demirkıran. 2021. Light Metals 2021. Light Metals 2021 220 226 .
Suman Kalyan Das, Suresh Gain & Prasanta Sahoo. 2021. Welding Technology. Welding Technology 1 39 .
Adel Boucherit, Said Abdi, Mouloud Aissani, Brahim Mehdi, Khadidja Abib & Riad Badji. (2020) Weldability, microstructure, and residual stress in Al/Cu and Cu/Al friction stir spot weld joints with Zn interlayer. The International Journal of Advanced Manufacturing Technology 111:5-6, pages 1553-1569.
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Saliha Gachi, Mouloud Aissani, Thierry Baudin, Anne.Laure Helbert, François Brisset, Sébastien Gautrot, Marie-Hélène Mathon, Djamel Bradai & Fouad Boubenider. (2020) The Microstructure, Texture and Mechanical Properties of Friction Stir Welded Aluminum Alloy. Russian Journal of Non-Ferrous Metals 61:5, pages 523-533.
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M. Vetrivel Sezhian, R. Ramadoss, K. Giridharan, G. Chakravarthi & B. Stalin. (2020) Comparative study of friction stir welding process and its variables. Materials Today: Proceedings 33, pages 4842-4847.
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Piyush Gulati, Dinesh Kumar Shukla, Akash Gupta, Manpreet Singh, Rajeev Kumar & Jaiinder Preet Singh. (2020) Microstructural analysis of friction stir welded Mg AZ31 alloy. Materials Today: Proceedings 26, pages 1145-1150.
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C. Chanakyan, S. Sivasankar, M. Meignanamoorthy, M. Ravichandran, S.V. Alagarsamy, S. Dinesh Kumar & S. Sakthivelu. (2020) Friction stir processing (FSP) of numerical study based on design of experiment-review. Materials Today: Proceedings 27, pages 748-751.
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Tanvir Singh, S.K. Tiwari & D.K. Shukla. (2020) Mechanical and microstructural characterization of friction stir welded AA6061-T6 joints reinforced with nano-sized particles. Materials Characterization 159, pages 110047.
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Bhanodaya Kiran Babu Nadikudi. 2020. Emerging Trends in Mechanical Engineering. Emerging Trends in Mechanical Engineering 65 72 .
I Vysotskiy, S Malopheyev, S Mironov & R Kaibyshev. (2019) Friction-stir welding of Al-Mg-Mn-Zr sheets by using a hemispherical tool. IOP Conference Series: Materials Science and Engineering 672:1, pages 012040.
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S. Baragetti, E. Borzini, Ž. Božic & E.V. Arcieri. (2019) On the fatigue strength of uncoated and DLC coated 7075-T6 aluminum alloy. Engineering Failure Analysis 102, pages 219-225.
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Md Parwez Alam & A N Sinha. (2019) Fabrication of third generation Al–Li alloy by friction stir welding: a review. Sādhanā 44:6.
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R. Abrahams, J. Mikhail & Panahsadat Fasihi. (2019) Effect of friction stir process parameters on the mechanical properties of 5005-H34 and 7075-T651 aluminium alloys. Materials Science and Engineering: A 751, pages 363-373.
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Sara Bocchi, Marina Cabrini, Gianluca D’Urso, Claudio Giardini, Sergio Lorenzi & Tommaso Pastore. (2018) The influence of process parameters on mechanical properties and corrosion behavior of friction stir welded aluminum joints. Journal of Manufacturing Processes 35, pages 1-15.
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Murshid Imam, Yufeng Sun, Hidetoshi Fujii, Ninshu MA, Seiichiro Tsutsumi, Shuja Ahmed, Viswanath Chintapenta & Hidekazu Murakawa. (2018) Deformation characteristics and microstructural evolution in friction stir welding of thick 5083 aluminum alloy. The International Journal of Advanced Manufacturing Technology 99:1-4, pages 663-681.
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Moustafa Boukraa, Nadhir Lebaal, Amina Mataoui, Abdelhakim Settar, Mouloud Aissani & Nacer Tala-Ighil. (2018) Friction stir welding process improvement through coupling an optimization procedure and three-dimensional transient heat transfer numerical analysis. Journal of Manufacturing Processes 34, pages 566-578.
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Noor Zaman Khan, Mohammed Ubaid, Arshad Noor Siddiquee, Zahid A Khan, Abdulrahman Al-Ahmari, Xizhang Chen & Mustufa Haider Abidi. (2018) Microstructural features of friction stir welded dissimilar Aluminium alloys AA2219-AA7475. Materials Research Express 5:5, pages 056531.
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Prakash Dabeer & Gurunath Shinde. (2018) Perspective of Friction Stir Welding Tools. Materials Today: Proceedings 5:5, pages 13166-13176.
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Yaping Bai, Yongchun Guo, Jianping Li, Zhong Yang & Jia Tian. (2016) Effect of Al 2 O 3 nanoparticle reinforcement on the mechanical and high-temperature tribological behavior of Al-7075 alloy . Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology 231:7, pages 900-909.
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Tianjian Li, Tao Wu, Xiaohong Ding, Hong Chen & Lei Wang. (2016) Design of an internally cooled turning tool based on topology optimization and CFD simulation. The International Journal of Advanced Manufacturing Technology 91:1-4, pages 1327-1337.
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Nilesh D Ghetiya & Kaushik M Patel. (2017) Welding speed effect on joint properties in air and immersed friction stir welding of AA2014. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231:5, pages 897-909.
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Gianluca D’Urso, Claudio Giardini, Sergio Lorenzi, Marina Cabrini & Tommaso Pastore. (2017) The influence of process parameters on mechanical properties and corrosion behaviour of friction stir welded aluminum joints. Procedia Engineering 207, pages 591-596.
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Mao Yuqing, Ke Liming, Liu Fencheng, Chen Yuhua & Xing Li. (2016) Effect of tool pin-tip profiles on material flow and mechanical properties of friction stir welding thick AA7075-T6 alloy joints. The International Journal of Advanced Manufacturing Technology 88:1-4, pages 949-960.
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V. Saravanan, S. Rajakumar, Nilotpal Banerjee & R. Amuthakkannan. (2016) Effect of shoulder diameter to pin diameter ratio on microstructure and mechanical properties of dissimilar friction stir welded AA2024-T6 and AA7075-T6 aluminum alloy joints. The International Journal of Advanced Manufacturing Technology 87:9-12, pages 3637-3645.
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S.M. Bayazid, H. Farhangi, H. Asgharzadeh, L. Radan, A. Ghahramani & A. Mirhaji. (2016) Effect of cyclic solution treatment on microstructure and mechanical properties of friction stir welded 7075 Al alloy. Materials Science and Engineering: A 649, pages 293-300.
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N. Bhanodaya Kiran Babu, M. J. Davidson & A. Neelakanteswara Rao. (2014) Investigation on the Influence of the Lubrication on the Formability of Dissimilar Tailor Welded Blanks. Transactions of the Indian Institute of Metals 68:4, pages 529-534.
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Bhanodaya Kiran Babu NADIKUDI, M.J. DAVIDSON, Neelakanteswara Rao AKASAPU & M. GOVINDARAJU. (2015) Formability analysis of dissimilar tailor welded blanks welded with different tool pin profiles. Transactions of Nonferrous Metals Society of China 25:6, pages 1787-1793.
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Şefika Kasman & Fatih Kahraman. (2013) Investigations for the effect of parameters on the weld performance of AA 5083-H111 joined by friction stir welding. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 228:8, pages 937-946.
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Kathryn J. Dharmaraj, Chase D. Cox, Alvin M. Strauss & George E. Cook. (2014) Ultrasonic thermometry for friction stir spot welding. Measurement 49, pages 226-235.
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S. Baragetti & G. D’Urso. (2014) Aluminum 6060-T6 friction stir welded butt joints: fatigue resistance with different tools and feed rates. Journal of Mechanical Science and Technology 28:3, pages 867-877.
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Afshin Emamikhah, Alireza Abbasi, Ali Atefat & M. K. Besharati Givi. (2013) Effect of tool pin profile on friction stir butt welding of high-zinc brass (CuZn40). The International Journal of Advanced Manufacturing Technology 71:1-4, pages 81-90.
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V. Infante & C. Vidal. 2014. Advances in Friction-Stir Welding and Processing. Advances in Friction-Stir Welding and Processing 199 240 .
Cemal Meran & Olcay Ersel Canyurt. (2013) Joint strength of friction stir welded AISI 304 austenitic stainless steels. International Journal of Materials Research 104:12, pages 1197-1204.
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Yanni Wei, Jinglong Li, Jiangtao Xiong & Fusheng Zhang. (2013) Effect of Tool Pin Insertion Depth on Friction Stir Lap Welding of Aluminum to Stainless Steel. Journal of Materials Engineering and Performance 22:10, pages 3005-3013.
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Şefika Kasman. (2013) Optimisation of dissimilar friction stir welding parameters with grey relational analysis. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 227:9, pages 1317-1324.
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M. Selvaraj, Vela Murali & S.R. Koteswara Rao. (2013) Thermal model for friction stir welding of mild steel. Multidiscipline Modeling in Materials and Structures 9:1, pages 49-61.
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