Tool Design and Material Selection Trends: Emerging Frontiers in Friction Stir Welding and Processing

Abstract

Friction stir welding (FSW) represents a solid-state welding technique wherein joining occurs through the frictional heat generated between a non-consumable tool and the parent material. This process offers several advantages over fusion welding methods due to its lower processing temperatures. The quality of FSWed joints significantly relies on the characteristics of the tool and various process parameters involved. The tool geometry in FSW comprises a tool shoulder and a probe, with the latter being a crucial element susceptible to wear. Tool wear is particularly concerning, especially when welding high-temperature strength materials like Ni superalloys. Hence, this chapter delves into discussions regarding tool geometries and materials aimed at enhancing the weld strength of FSWed joints.