The Effect of Auxiliary Electrical Energy Engineering Friction Stir Welding Technology (EAFSW): A Review

Abdulhak Sami; Alaa Daham Younis

doi:10.71229/0yak4s53

Authors

Abdulhak Ahmed Department of Mechanical Engineering, University of Mosul, Mosul, Iraq
Alaa Daham Younis Department of Mechanical Engineering, University of Mosul, Mosul, Iraq..

DOI:

https://doi.org/10.71229/0yak4s53

Keywords:

Friction stir welding, Electric assisted friction stir welding (EAFSW), Electric current, Microstructure, Auxiliary energy

Abstract

Friction Stir Welding (FSW) has been recognized as a reliable and versatile solid-state joining process capable of providing high-quality joints without any melt-related distortions. Despite the above-mentioned advantages, traditional FSW has certain drawbacks related to the large values of process forces and torque, the fast wear of the tool, and the limited ability to be used with high-strength metals and hard-to-weld materials (steels, titanium alloys). Various modifications of FSW utilizing auxiliary energy sources have been proposed for overcoming these deficiencies, but Electrically Assisted Friction Stir Welding (EAFSW) has gained much popularity during the last twenty years [1], [12]. In EAFSW, an electric current is fed into the rotating tool and/or the work piece, thus creating the localized Joule heat and sometimes a thermal electro plastic effect resulting in the softening of material ahead and around the tool and reducing the flow stresses of the welding materials. Consequently, the application of an electric current allows lowering the axial force, traverse force, and torque, extending the life of the tool, increasing the speed of welding, and expanding the spectrum of materials that can be welded together [2],[5]. The current paper reviews the results obtained in the field of EAFSW and focuses on the physical principles and mechanisms behind EAFSW, electrode design and circuit configuration, effects of electrical parameters on forces and torque, microstructure and mechanical properties of aluminum, magnesium, titanium, steel and dissimilar materials and composites joints made using EAFSW, numerical simulations and comparisons with other auxiliary-energy-assisted FSW processes. Finally, principal problems associated with current distribution, electrode wear, arcing, safety and cost factors, as well as the necessity of electro-thermo-mechanical modeling will be highlighted in this review.

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