Friction-based welding processes: friction welding and friction stir welding

TLDR

Friction‑based welding processes are efficient solid‑state metal joining techniques that produce sound joints with low energy consumption and environmental friendliness by generating elevated temperatures through mechanical friction. Friction welding (FRW) fuses materials by direct contact friction between workpieces, whereas friction stir welding (FSW) employs a rotating, non‑consumable tool to stir and consolidate the joint, with key process parameters such as rotational speed, welding speed, axial force, and tool geometry influencing joint properties. Compared to FRW, FSW offers superior joint quality, better adaptability to modern technologies, optimized process parameters, and the capability to join a wide range of dissimilar metals and alloys, though both processes have distinct advantages and drawbacks.

Abstract

Friction-based welding processes are considered as very efficient solid-state metal joining processes due to soundness of the welded joint with remarkably less energy consumption and environmentally friendly. The terminology behind these processes is to make use of elevated temperatures caused by the mechanical friction at contacting surfaces to fuse materials together. Several different friction-based welding techniques are classified briefly explaining their mechanisms to show a comparison between friction welding (FRW) and friction stir welding (FSW). In FRW contact between the specimens itself induce friction, while FSW uses a non-consumable rotating tool to fuse material at the junction. Numerous advantages and drawbacks exhibited by both the processes are compared by overviewing the current researches. Also extensive focus on the various factors influencing the properties of FSW joints such as rotational speed, welding speed, axial force, tool geometry, and defects are studied. FSW displayed superiority in welded joints as regards adaption to modern technologies, optimized process parameters, and the ability to join a wide variety of dissimilar metals and alloys.