A Contemporary Review on Friction Stir Welding of Circular Pipe Joints and the Influence of Fixtures on This Process

Abstract

The permanent metal joining processes play a vital role in assembling the complex aluminium structures of the aerospace, automotive, marine, and oil industries. The invention of friction stir welding (FSW) redefined the mechanism of metal joining to produce high-quality welds by eliminating the consumption of electrodes and shielding gases, resulting in economical processes. Research works still lack to explore the application of FSW in complex geometries. In this view, the present work reports a critical review of various geometries welded by FSW, mainly circular geometries that are majorly used in the oil and gas industries. The various aspects of the FSW of pipes, such as process facilitation, process parameters, tool material selection, and tool design selection are discussed. The paper also presents insights into the parameters responsible for the weld quality, the feasibility of optimization techniques, and the status of various fixture arrangements. The facilitation requisites for FSW of pipes are also provided based on the reviews made. The review concludes by discussing the challenges associated with the FSW of pipes, economic aspects, and future research directions.

Feasibility of orbital friction stir welding on clad pipes of API X65 steel and Inconel 625

“…FSW uses the friction energy produced between the materials to be joined and a non-consumable rotating tool. Two approaches are used in orbital FSW: in the first, the pipe rotates while the rotating tool remains stationary; and in the second, the entire tool head rotates while the pipe remains stationary 8 . As for the classical FSW, severe plastic deformation and material flow occur along the welding path.…”

“…Although FSW is successfully applied to sheets of various materials, orbital FSW involves challenges to be overcome since there are difficulties associated with the clamping device 8 , 12 . Challenges of FSW to complex and circular-shaped joints were recently reviewed by Senthil et al 8 , where the clamping system was one of the most significant factors for the welding process itself. For instance, due to the high forces during FSW, internal support of the pipes is required.…”

“…Another difference when welding pipes is the contact of the tool with the parts to be joined, e.g., depending on the diameter of the pipe, the curvature of the pipe results in a non-complete contact of the tool shoulder with the workpiece, thus influencing the material flow and heat generation 12 , 13 . Senthil et al 8 also pointed out that before FSW can be considered for industrial pipe joining, a deep understanding of the influence of the clamping system is essential.…”

A Review on Tool Pin Geometry of Friction Stir Welding

“…These days, FSW is being progressively introduced to the at sea structure and energy sectors. [8][9][10], FSW is also highly advantageous in terms of economic and environmental considerations [11][12][13]. In FSW, primary and secondary parameters are the two groups of factors that affect the quality of the weld joint.…”

Modification of Energy Saving for Safe Welding Process: Case Study in Manufacturing of SME

“…Several welding processes are employed depending on the type of metal and required strength. A fixture maintains the workpiece in the horizontal and vertical orientations during pipe and plate welding [2]. Metal inert gas (MIG) welding is a standard welding process used in the industrial and construction sectors [3].…”