A Review of Conical Tool feature variation on Friction Stir Welding (FSW) Process

Harsh M Patel; Kaushal H. Bhavsar

CALL FOR PAPERS : Feb-2026

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25-Feb-26

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A Review of Conical Tool feature variation on Friction Stir Welding (FSW) Process

Author(s):

Harsh M Patel , LDRP Institute of Technology and Research, Gandhinagar-382015, India; Kaushal H. Bhavsar, LDRP Institute of Technology and Research, Gandhinagar-382015, India

Keywords:

Friction stirs welding (FSW); conical tool; aluminium alloy

Abstract:

Friction stir welding (FSW) is an innovative solid state joining process, developed by The Welding Institute, UK for joining aluminum, magnesium, zinc and copper alloys. FSW is being used in aerospace, automotive, rail, marine industries, fabrication, etc. FSW is more beneficial over traditional welding process, particularly in the areas of weld quality and environmental impacts. The FSW process parameters such as tool rotation and transverse speed, tool design, axial force, play a major role in deciding the weld quality. In this article, we are going to analyze joining of two same materials by varying affecting parameters and to carry out the optimized set of parameters, which will give high strength for particular pair of dissimilar materials. An attempt has been made to join aluminum alloy 6351 T6 plate having dimension of 120*50*12 with three different featured conical tool friction stir welding (FSW). FSW is more eco-friendly and refine process which give higher joint efficiency than fusion welding process if proper parametric is used. Process parameter like Rotational speed, welding speed, Fixture design, Tool Design, Tool Pin are studied in this research work. Welding speed or transverse speed, Range of RPM and tool features are chosen for Experimental work. Check the fatigue test on different range, speed and conical tool using the welding process and check the fatigue life of weld specimen.