An introduction to friction stir welding

By Jeff Defalco, Contributing Writer

September 15, 2009

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminum alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material.

Friction stir welding (FSW) is a relatively new joining process that has been used for high production since 1996. Because melting does not occur and joining takes place below the melting temperature of the material, a high-quality weld is created. This characteristic greatly reduces the ill effects of high heat input, including distortion, and eliminates solidification defects. Friction stir welding also is highly efficient, produces no fumes, and uses no filler material, which make this process environmentally friendly.

History

Friction stir welding was invented by The Welding Institute (TWI) in December 1991. TWI filed successfully for patents in Europe, the U.S., Japan, and Australia. TWI then established TWI Group-Sponsored Project 5651,”Development of the New Friction Stir Technique for Welding Aluminum,” in 1992 to further study this technique.

The development project was conducted in three phases. Phase I proved FSW to be a realistic and practical welding technique, while at the same time addressing the welding of 6000 series aluminum alloys. Phase II successfully examined the welding of aerospace and ship aluminum alloys, 2000 and 5000 series, respectively. Process parameter tolerances, metallurgical characteristics, and mechanical properties for these materials were established. Phase III developed pertinent data for further industrialization of FSW.

Since its invention, the process has received world-wide attention, and today FSW is used in research and production in many sectors, including aerospace, automotive, railway, shipbuilding, electronic housings, coolers, heat exchangers, and nuclear waste containers.

“If you can’t stand the heat, get out of the kitchen.”

This expression makes absolutely no sense if you’re in the profession of welding.

#1:  If you can’t stand the heat, why the heck are you a welder?

#2:  There is no kitchen.  What kitchen?  If you’re welding in a kitchen, get out of that kitchen. Right now! There are gas mains!

#3:  If you can stand the heat, and you’re not in a kitchen, then why would you move?  Stand right there!

In fact, let’s add some more heat.  Let’s add some… friction.

That’s right, you heard me. Friction, as in friction stir welding. FSW. It’s all the rage in… in…

Just read.

An introduction to friction stir welding

By Jeff Defalco, Contributing Writer
September 15, 2009

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminum alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material.

Friction stir welding (FSW) is a relatively new joining process that has been used for high production since 1996. Because melting does not occur and joining takes place below the melting temperature of the material, a high-quality weld is created. This characteristic greatly reduces the ill effects of high heat input, including distortion, and eliminates solidification defects.

Friction stir welding also is highly efficient, produces no fumes, and uses no filler material, which make this process environmentally friendly.

CONTINUE READING ONLINE ->

ROBOTS ARE TAKING OVER THE WORLD!!!

Ok, not the whole world – just the job parts…

ABB’s VirtualArc robot welding simulation software teaches robots without waste

19 August 2009

ABB says its VirtualArc robot welding simulation software allows welding robots to achieve precise, clean, mass-produced welds.

Human welders draw on experience, intuition and trial-and-error to establish the right parameters for a welding job. Transferring this skill to robots can be complex.

While robots speed productivity, and provide accurate repeatability of tasks, they can only get the welding right if they have been programmed correctly.

“Teaching” a robot to perform a arc-weld, means providing it with the knowledge that comes from many years of human experience and the intuition that enables it to choose the appropriate process for a new task.

Traditionally, experienced welder set up the welding parameters on robots by performing a series of test welds and adjusting parameters to hone the result. This approach uses up materials, manpower and energy.

CONTINUE READING ONLINE ->

So, what do you think?  Yay or nay to robots on the job?

Want some free Miller welding equipment???

This month, Miller Electric is giving away over $2,000 worth of welding supplies to one lucky grand prize winner!

To enter for a chance to win, just sign up for one of Miller’s eNewsletters to keep in touch with industry news and the latest how-to advice!

Complete Grand Prize Package:

• Choice of Millermatic® 211 Auto-Set™ MIG welder, Diversion™ 165 TIG welder, OR Spectrum® 375 X-TREME plasma cutter
• ArcStation™ welding workbench
• Performance Series™ auto-darkening welding helmet
• Arc Armor combo welding jacket
• Pair of MIG, TIG, and Metalworker gloves
• iPod touch

There is a new welding process, recently developed in Europe, that is said to not only improve welds but also lower the skill required to make them.  It uses a “manual and automated GTAW wire feed control combined with a hot-wire power source” that improves the wire feed, weld pool, and weld deposition and decreases gas consumption.

Enhancing the GTAW process

By Ed Craig, Contributing Writer
September 15, 2009

Gas tungsten arc welding (GTAW or TIG), a popular process for high-quality manual welding, has its limitations and requires highly skilled operators. A process used in Europe addresses those limitations, enhances productivity and weld quality, and reduces the skill level required to GTAW.

For at least six decades, traditional gas tungsten arc welding (GTAW or TIG) has been considered the process of choice for attaining high-quality welds in any metal application. However, this process has certain drawbacks, such as the weld energy limitation influenced by the weld pool dynamics and typically slow manual wire feed rates. Manual GTAW requires highly skilled operators who possess the dexterity necessary to feed the wire. Manual GTAW techniques vary, and the weld-wire-to-arc and weld puddle placement are inconsistent.

CONTINUE READING ONLINE ->

If you already know all about plasma cutting, then this article is not for you, but if you’re new to the industry, or investigating all the metal fabrication processes out there, then check it out.

Plasma cutting and how it works

By Kent Swart, Contributing Writer
August 11, 2009

What is plasma cutting, and when is it your best metal cutting option? What information do you need to choose the right plasma system? This article answers these questions and more about plasma cutting.

The basic technology for plasma cutting has been around for decades. Researchers and engineers remain focused on increasing cut speed, improving cut quality, and extending consumable life, while making systems smaller and more powerful.

What Is Plasma Cutting?

Once a gas is heated to an extremely high temperature and ionized, it becomes electrically conductive and is considered to be plasma. Plasma arc cutting and gouging processes use plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the arc’s heat and then blown away.

CONTINUE READING ONLINE ->

And check out this article about plasma arc cutting over at Arc-Zone.com… tips to maximize the life of your PAC consumables and enhance your cut quality –>

…and check out the line of Plasma Arc Cutting Torches and replacement parts at Arc-Zone.com.

Interested in saving money while you’re welding this autumn? Check out this article over at Welding Magazine — it lists ten simple ways that you stay thrifty, and that’s just when you’re using your MIG gun!

10 Money-Saving Tips for Semi-Automatic MIG Guns

By DAVID BELLAMY | Jul 1, 2009 12:00 PM

Your welding operation, just like any other portion of your business, offers opportunities to conserve resources.

The economy continues to challenge all of us, and it seems everyone is watching his or her finances (at home and on the job) and looking for innovative ways to save money. Your welding operation, just like any other portion of your business, offers opportunities to conserve resources. Consider these 10 money-saving tips for MIG gun care and maintenance, and don’t be surprised to discover you will improve your welding performance in the effort.

TIP #1: PROTECT YOUR ASSETS

Keep your nozzles, retaining heads (diffusers) and contact tips in the original shipment package until you are ready to use them. This prevents scratches and/or dents where spatter can accumulate and will make them last longer. It also prevents dirt, oil or other debris from adhering to the consumables and inadvertently entering the weld puddle.

CONTINUE READING ONLINE ->

And did you know that Arc-Zone.com carries a full line of MIG Guns and replacement parts, MIG nozzle cleaning stations, and MIG Wire feeders? check it out… then let us know what YOU are doing to save cash! Share your best ideas with the rest of us!

How does your structural steel shop measure up?  The Fabricator magazine has some helpful guidelines that you can use to see whether or not your shop hits the mark.

1. How close can your drilling operations get to 50 inches per minute?

2. Can you claim material handling costs of less than $50 every time you move a beam?

3. Can your plasma cutting system deliver a cut with a tolerance of 0.010 in.?

4. Can your software packages accommodate the use of CAD models to generate CNC codes automatically?

Technologies help to make shops structurally sound

4 benchmarks your operations need to beat

By Michael Bishop, Contributing Writer

Photo courtesy of Peddinghaus Corp.

Tough economic conditions have hit the construction industry as hard as they have many other industries. These problems in commercial construction are affecting structural steel fabricators. New technologies are especially benefiting four important structural steel fabricating processes by reducing labor costs. These represent some of the bigger developments in recent years.

CONTINUE READING ONLINE ->

At Arc-Zone.com we’re always on the lookout for new business opportunities and ways to streamline operations… what are YOUR best tips for streamlining operations? and How are YOU weathering the economy?

Check out the July issue of Practical Welding Today for an article written by our very own Jennifer Simpson, Arc-Zone.com‘s director of marketing and new media!  And the cover photo is Joe Welder laying down some awesome TIG welds, shot in studio C by our talented Graphics guy, Matt Munz. Good job team!

Know your TIG torch

Advice and maintenance practices to ensure quality
By Jennifer Simpson
July 1, 2009

Even though money is tight, saving it by purchasing less reputable GTAW torches or skimping on maintenance practices can cause more harm than good in the long run.

Photos courtesy of Matt Munz, Arc-Zone.com Inc., Carlsbad, Calif.

When times are tough our initial instinct is to save money and buy cheap. That’s not always the best strategy, especially when you’re looking at a new gas tungsten arc welding (GTAW) torch.

One of the biggest differences between a low-quality and high-quality torch is the materials used in manufacturing it, as well as the production process. Quality torches last longer, run cooler, provide a stable arc, and offer overall improved weld quality.

CONTINUE READING ONLINE ->

Want to read some more articles written by Jennifer?  Check out these two other fabricator articles: Obtenga la conexión and Optimize your plasma performance, co-written by me, Jim Watson, aka Joe Welder.

And when you’re ready to buy a quality TIG Torch, check out Arc-Zone.com. We deliver the best quality TIG torches on the market, from CK Worldwide to Weldcraft. At our online store you’ll also find accessory kits, all the connectors you need not to mention replacement parts and tungsten electrodes….

This blog offers a fresh and brutally honest perspective on welding industry news, reviews of innovative companies and products, and profiles of those who are making an impact in the metal fabrication industry.

What we hope you’ll find: tips, tidbits, perspectives you won’t find elsewhere, as well as insights, original interviews and more that should be of interest to the metal fabrication market worldwide. We promise to keep the content fresh, and interesting.

This Blog is primarily written by Jim Watson (aka Joe Welder), a master fabricator, welding equipment designer, industry professional, online distributor, and owner of Arc-Zone.com, Inc.

Contact us with your suggestions, comments, corrections, errors, praise or flames. We will be editing comments for SPAM, and inappropriate content (you know what that means!)