Friction Stir Welding (FSW) is a relatively new process of material joining that is superior to most conventional approaches to welding. In this article FSW was compared with several conventional welding methods such as TIG, MIG, brazing, and EBW emphasizing the advantages of FSW.
FSW vs. TIG welding
TIG welding also known as Tungsten Inert Gas welding is an arc welding technique that is common due to its ability to use a non-consumable tungsten electrode to create the weld. While TIG welding is known for its precision and ability to weld a variety of metals, FSW offers several advantages: While TIG welding is known for its precision and ability to weld a variety of metals, FSW offers several advantages:
- No melting: In contrast to TIG welding where it uses the use of melding the base metals and filler material, FSW uses solid phase joining. This does away with problems such as porosity and cracking which are rife where TIG welding is involved.
- Better material properties: Basically, FSW does not alter the mechanical properties of the joined materials in a way that is detrimental to the material which is useful for heat sensitive alloys. TIG welding on the other hand can change the properties of the metals, due to high heat input that is used.
- No consumables required: Compared to TIG welding, FSW does not need filler materials, and the shielding gases have been eliminated therefore cutting down on material and environmental costs.
FSW vs. MIG welding
Another type of arc welding is MIG (Metal Inert Gas) welding which is achieved utilising a consumable core wire electrode and an inert gas shield to the weld zone. Compared to MIG welding, FSW offers several advantages:
- Reduced defects: FSW does not heat the base materials and create a weld, this greatly minimizes the chances of welding flaws for instance porosity and slag inclusion that are typical of MIG welds.
- No need for protective gas: One more advantage of FSW is that it could be performed in an open air environment, also there is no need for shielding gases, which decreases the cost of welding immensely and also decreases the effect of welding on environment.
- Enhanced weld strength: Because MIG welding tends to transfer a high amount of heat and energy to the workpiece, FSW often yields better and more consistent welds with regard to heat-sensitive alloys.
FSW vs. brazing
Brazing for example, a filler material is used it melts at a higher temperature than the parent metal and wets the surface of the two metals to be joined to form a bond. While brazing is suitable for joining dissimilar materials and is less heat-intensive, FSW has several advantages:Comparing with brazing, FSW is more suitable for joining dissimilar materials and this process is not so energy-consuming So FSW has many advantages:
- Stronger joints: FSW results in the formation of a new solid-state joining where the base metal is brought into direct mechanical contact causing the base metal bond to be stronger and highly elastic than the one created in brazing by using a molten filler metal.
- No filler materials: In FSW as described before no extra filler material or fluxes are used which makes the process easier and it has less possibility to be contaminated.
- Less thermal distortion: Some of the methods that are used include brazing and the fact that use FSW has fewer thermal distortions and stress are induced at the materials when they are heated.
FSW compared with others welding techniques such as electron beam welding (EBW).
Electron Beam Welding (EBW) is a technique by which the components are joined through heating to a required temperature by means of a focused high energy electron beam. While EBW is known for its precision and ability to weld thick sections, FSW offers several benefits:As stated earlier EBW provides high level of accuracy to weld thick sections but FSW has following advantages:
- No vacuum required: A fourth disadvantage of EBW is that it should be performed in a vacuum environment whereby, the overall process, and therefore, the cost is magnified. However, while one can only turn to FSW to get the kinds of information it carries, FSW operates in an open manner and is therefore more accessible, cheaper than traditional research.
- Broader material range: With FSW, it is possible to rivet an incredibly diverse range of materials such as high-strength alloys, dissimilar metals and so on whereas, in EBW, it face the issues of type and thickness of material.
- Lower cost and complexity: With regards to FSW systems, the article reveals that they are far cheaper and less complex compared to what is needed for EBW systems thus giving more support to FSW as the more business-oriented option.
To sum up the kinds of advantages FS- Welding has against the conventional welding, one can list the following: With reduced number of defects in the welds increased strength of the welded connection and lesser impact on the environment.
However, each form of welding is useful in its way and ideal for particular uses; FSW has a lot to offer in terms of addressing needed modern applications that come with its solid-state aspect that needs no filler material and its versatility.
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