Friction Welding & Friction Stir Welding - UNIDO-ICAMT

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About the Partner organizationsThe International Centre for Advancement of Manufacturing Technology (ICAMT) is anInternational Technology Centre of the United Nations Industrial Development Organization(UNIDO) promoting manufacturing technologies & innovations as the means to enhanceindustrial competitiveness in India & other developing countries. It provides a platform foreffective dissemination& transfer of knowledge on technological advances amongst variousindustrial sectors with a focus on small & medium enterprises. It acts as a catalyst in bridging thegap between the emerging market demands for new products, industry needs in emergingtechnologies & the existing technology base. Through its international network, globalrecognition & its engagement at the grass root level, UNIDO-ICAMT is a true technologypartner in progress.Indian Welding Society is a Professional body, Registered under Societies Registration Act. TheMission of this Society is to serve as knowledge sharing platform in Welding and allied fieldsand spread the latest developments in welding technology through different Centers and Zonesspread across the country.PES Institute of Technology, Bangalore is a premier autonomous engineering institution thatpromotes technological excellence.ETA Technology, Bangalore is a global leader in the manufacture of a wide range of high-techFriction welding machines, Linear Friction welding machine, Friction stir welding machines &special purpose machines widely used in the automotive components manufacture, Aerospacecomponents & Drill pipe manufacture to mention a few. Driven by innovation ETA excels inproviding engineering solution for various industrial applications. It is also part of the BangaloreMachine Tool Cluster.Indian Institute of Science (IISC), Bangalore is a premier institution of higher education“University of Research” in India with a hundred years of dedication.****6
Technical sessionsIn the morning of the first day’s session, three technical papers were presented, one on FrictionWelding and two papers on Friction Stir welding Technology. Mr Kasturi T.S., Chief ExecutiveOfficer, ETA Technology, Bangalore explained how the process of rotary friction welding isimplemented in a modern day Machine. The principal mechanical elements as well as control &display Elements of a typical Friction Welding Machine was elaborated. He also narrated theoperation sequence of the machine and how to set different process parameters in the machine.He brought out various practical considerations to make a quality weld joint. He also deliberatedon different types of commercially available Friction welding equipments as mentioned below:- 125 T single head Friction welding machine- 150 T double head Friction welding machine- 3 T vertical Friction welding machine- 15 T Friction welding machine with built-in deflash- 6 T slant head Friction welding machineDr V. Balasubramanian, Professor & Director, Centre for Materials Joining & Research(CEMAJOR), Department of Manufacturing Engineering, Annamalai University delivered a talkon “Friction Stir Welding: A Revolutionary Process”. He narrated how Friction WeldingTechnology got evolved in U.K. and gave a historical perspective of the process basically meantfor plates and structural configurations. He spoke at length on the use and adaptation of thistechnology to Cast and wrought Aluminum alloy products, Copper alloys, Magnesium alloys,Carbon steels and Stainless steels. He also brought out safe welding windows for each categoryof the metal so as to obtain defect free welds.Dr Satish V. Kailas, Professor, Department of Mechanical Engineering, Indian Institute ofScience, Bangalore delivered a talk on “Friction Stir Welding and Friction Stir Processing”. Heexplained the principle of Friction Stir Welding and Friction Stir Processing wherein process, anon-consumable rotating tool, which has a shoulder, is plunged into the weld interface andmoved forward. The shoulder generates significant amount of heat in the material being welded,increasing it temperature and lowering its flow stress. The rotating action stirs the material andthe forward motion makes the material from the front of the weld move to the rear portion of theweld. The large amount of strain induced and the stirring action of the tool eliminates theoriginal weld interface and welds the two plates together. He also emphasized that among themany parameters that control the weld quality and strength are the tool geometry, tool rpm,traverse speed, normal load applied by the tool and weld interface position. While the largenumber of parameters allow for precise control of the weld strength, it also poses a challenge onwhat are the optimal weld parameters, especially because they are interlinked in a, many-attimes,non-linear relationship. Further, he focused on how to go about reaching this “optimalpoint”, for a given tool geometry, with minimal number of trials. The effect of the normal loadapplied by the tool and tool interface position is specially emphasized on in this talk. He alsohighlighted how the process introduces a large strain on the deforming material and thus isamenable to being used to produce ultra-fine grained and near-nano grained material. Some ofthe work being done in this direction were presented and there was lively discussion.7
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Friction Welding & Friction Stir Welding - UNIDO-ICAMT

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