• Very- to ultra-fine grain size
• Low matrix dislocation density – high ductility
• Consolidation of materials with high porosity, such as machining swarf
• Larger sizes than other severe plastic deformation processes
• Can produce solid rods or tubular products
• Ability to disperse hard particles in a matrix without segregation

Tool choice is critical for friction stir welding. Joint design and welding machine capabilities dictate the best style to use.

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The most common tool types are conventional tools and self-reacting tools.

Conventional welding tools have a rotating pin – called a probe – and shoulder. They are used for butt or lap joints

Key components of this tool type include:

• Pin that stirs the joint and is slightly shorter than the thickness of the workpiece for butt joints and slightly longer for lap joints
• Shoulder that rides on the surface of the workpiece and prevents escape of the softened material
• Rigid anvil that supports the workpiece along the joint line

These tools may be monolithic or multi-component.

Self-reacting (bobbin) welding tools eliminate the need for a rigid anvil to react the forces of welding. Two shoulders, one on each side of the workpiece, are connected by a pin.

• Fixed-gap tools maintain a fixed spacing between the shoulders
• Variable-gap tools require a mechanism to actuate the pin and change the spacing between the shoulders

FSW operates just below the melting point of the workpiece material. That’s why it’s important to choose welding tool materials specifically designed for the workpiece material.

Aluminum welds at low temperature, so H13 tool steel is a good choice. Other materials used for aluminum include MP159 (not to be used for 5XXX aluminum alloys), tungsten carbide and other hot-work tool steels.

Steel welds call for either refractory or super-abrasive metal tools. Refractory metal tools, made from tungsten or tantalum, can be alloyed with rhenium, lanthanum, or other elements to increase strength. Polycrystalline cubic boron nitride (PCBN) tools can be made with different binders to tailor properties to different applications.

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Titanium welds require tools made from the same materials as for steel. However, not all tools for steel work in titanium.

Bond produces all types of friction stir welding tools. Our welding specialists can help guide the right selection, based on customer design or designs we produce. Learn more

BS EN ISO -2: - Friction Stir Spot Welding

BS EN ISO -2:: Friction Stir Spot Welding - Aluminium Design of Weld Joints

Welcome to the world of advanced welding techniques with the BS EN ISO -2: standard. This comprehensive guide is your key to mastering the art of friction stir spot welding, specifically tailored for aluminium materials. Released on January 25, , this standard is an essential resource for professionals in the welding industry, engineers, and designers who are looking to enhance their knowledge and skills in creating robust and efficient weld joints.

Overview of the Standard

The BS EN ISO -2: standard provides detailed guidelines and specifications for the design of weld joints using friction stir spot welding (FSSW) techniques. This method is particularly advantageous for aluminium, a material known for its lightweight and high-strength properties. The standard outlines the best practices and design considerations to ensure optimal performance and durability of welded joints.

Key Features

• Standard Number: BS EN ISO -2:
• Pages: 14
• Release Date: January 25,
• ISBN: 978 0 539 3
• Status: Standard

Why Choose Friction Stir Spot Welding?

Friction stir spot welding is a revolutionary technique that offers numerous benefits over traditional welding methods. It is a solid-state process, meaning that it does not involve melting the materials being joined. This results in several advantages:

• Improved Joint Strength: The absence of melting reduces the risk of defects such as porosity and cracking, leading to stronger and more reliable joints.
• Enhanced Material Properties: The process preserves the original properties of the base materials, maintaining their strength and integrity.
• Environmental Benefits: FSSW is an eco-friendly process that produces minimal emissions and waste, making it a sustainable choice for modern manufacturing.
• Cost-Effective: The efficiency of the process reduces energy consumption and material waste, leading to cost savings in production.

Applications of the Standard

The BS EN ISO -2: standard is applicable across a wide range of industries where aluminium is a key material. Some of the primary applications include:

• Automotive Industry: Used in the production of lightweight and fuel-efficient vehicles, enhancing performance and safety.
• Aerospace Sector: Essential for constructing aircraft components that require high strength-to-weight ratios.
• Construction: Ideal for building structures that demand durability and resilience.
• Consumer Electronics: Utilized in the manufacturing of devices that require precision and reliability.

Design Considerations

Designing weld joints using friction stir spot welding requires careful consideration of several factors to ensure optimal results. The BS EN ISO -2: standard provides guidance on:

• Material Selection: Choosing the right aluminium alloys that are compatible with FSSW techniques.
• Joint Configuration: Designing joints that maximize strength and minimize stress concentrations.
• Tool Design: Selecting and designing tools that are suitable for the specific welding application.
• Process Parameters: Optimizing parameters such as rotational speed, pressure, and dwell time to achieve the best weld quality.

Conclusion

The BS EN ISO -2: standard is an invaluable resource for anyone involved in the design and production of aluminium weld joints using friction stir spot welding. By adhering to the guidelines and specifications outlined in this standard, professionals can ensure the creation of high-quality, durable, and efficient welds that meet the demands of modern engineering and manufacturing.