Science of Innovation: Friction Stir Welding

Welding has long been used to join pieces of metal together. At the University of North Texas, Rajiv Mishra is using a form of welding in a new technology that can improve metal’s strength, toughness, and other properties and could bring new opportunities to the automotive and aircraft industries.
"Science of Innovation" is produced in partnership with the National Science Foundation and the United States Patent and Trademark Office.

[@frankduncan5685]

FSW was actually discovered during WWII by British machinists! In order to speed up machining of airplane parts, they tried placing two pieces of plate against each other so they could machine down the center finishing two parts in the same time as it took to do one. The tool steels not being nearly as good as they are today, they were usually not all that sharp. Consequently, when they tried to machine two pieces, they wound up with one piece where they were welded together! Needless to say, that wasn't helping the war effort so the effect was noted and abandoned.

[@EmpyreanLightASMR]

Very cool, thank you for the comment! Wish it had more upvotes

[@vahiidsabbaghi]

explained very good...comprehensive thanks a lot

[@saurabhsuman8759]

nice video :) explained very well

[@kexcz8276]

Excellent video about curious topic! Very helpful to me!

[@jamescox9483]

Steel to aluminum with some kind of cross polarity would be a game changer.

[@Nvelopmusic]

Ultrasonic welding can join steel to aluminum with enough force. Check out fabrisonic, they make 3d printers using that technology.

[@bongmerced5842]

Thats new , two different parent metal , i wonder how to make a WPS and welding qualification test for operators

[@paintfreek1357]

You can use FSW to bond dissimilar metals. The largest problem with those two is thier melt points are very different, and so are thier expansiveness. This leads to internal stresses.

[@saarthakshrivastava5559]

wow i was just searching for fsw and i found this, amazing work also proud that our country people are doing such work i am also graduating and intent to be a scientist its fantastic

[@Elimarzordan]

Hey, it's me Destin, welcome to Smarter Every day.

[@thannbanis3639]

Elimar Zordan identity theft is not a joke Jim.

[@amitube663]

it is an amazing joining mechanism for dissimilar materials.

[@sidharthcs2110]

Thanks Destin, ULA

[@nagarajtirumani4752]

10-06-2020 Very good innovative idea. !!!

[@internetuser3748]

We use friction stir welding at SpaceX for the propellant tank on the Falcon 9

[@danwhornham4037]

Bezos sent me here. Lex's podcast.

[@mrmrhla]

I hope that guy makes a ton of money and is living the good life! I love inventors.

[@dreamdiction]

1:15 He didn't invent it.

[@gabrielpaes9351]

@@dreamdiction he used it to enhance mechanical properties in metals though, which was even patented. (3:47) He is an inventor.

[@dreamdiction]

​@@gabrielpaes9351 It was already invented, it was already patented. There is nothing new here, this is fake news to attract investors who will lose their money.

[@MrDriftspirit]

He spents all the money in terrible ridiculous rings

[@vincentmakotsi6086]

Oh that's so good technology I do like it

[@macro820]

I would love to see how steels besides D2 react to this, specifically certain steels that can only be work hardened and cannot be heat treated.

[@michaelmartinez5217]

An weres your channel showing your point of view???

[@macro820]

​@@michaelmartinez5217 Sorry that I didn't make a video to express my one sentence

[@an3582]

@@michaelmartinez5217 Yo.... Why so aggressive?

[@jonbaker3728]

@@michaelmartinez5217 Where's

[@andrealiotta9397]

It's very amazing :-)

[@katsu-graphics5634]

This is called "Spin Welding", and I used it in 1982 at Molycorp, on polyolfin plastic. . . I see it's now made for metals.

[@thecma3]

This is different from spin welding. Spin welding involves actually heating the material in the components being fused to the melting/glass transition point. In friction stir welding, the material is only softened; it doesn't change phase.

[@ShivaKumar-hh1ko]

You please try in google... This was invented and made patent in the year 1991...

[@Tkm112093evadell]

Katsu-Graphics I guess you know more than Salvatore Bruno- President and CEO of ULA Rocket manufacturing... it’s called Friction Stir Welding but pretty much everyone who uses this. Spin welding requires actual melting of metals, this process is not changing any thermal properties.

[@arindambaruah5419]

Weird considering TWI was the first organisation to invent this process in 1991.

[@rb032682]

fascinating stuff

[@amirsafari7140]

Who is here after smarter every day ula tour??😁

[@lohriialo]

Last night after ULA tour video, I kept thinking why spacecraft uses stir welding and here I am 😁

[@MrH786]

Elon needs to learn from ULA. Isogrid with FSW. If you have access to Elon, tell him to watch that interview video.

[@amirsafari7140]

@@MrH786 i am sure they are using iso grid for falcons,but star ship doesn't need that because it is made from stainless steel

[@MrH786]

If you watch the Padre videos, you will notice that the stainless steel is too wobbly to assemble because there is no skeletal support system. SpaceX is also using basic fusion welding techniques with individual welders. These two things will make the Starship prone to numerous defects or failures. Even if they get a Starship up, there is a high probability it could break apart or fail due to stress issues.

[@amirsafari7140]

@@MrH786 the structural support will be available when tank goes under internal pressure,and ir doesn't need skeleton support,and you cant stir weld stainless steel,even ula was welding steel parts normally in smarter every day video

[@nlo114]

Now used for joining rocket body-panels together

[@brooksriess748]

Would it be possible to create a manual friction stir welding machine? This will be a phenomenal component for manufacturing in the shop. But this would revolutionize welding if there was an application for stir welding to be used in the field.

[@user-es6gq3je4b]

As far as i understand, it requires constant high pressure. I think it'll b difficult to make a manual machine for this.

[@dr.aliyasirhasan3986]

thank you for every things

[@iac4357]

Here after watching Below Decks Season 7, featuring the Yacht "Home"; with what appears to be a nearly vertical Bow, apparently welded using this Method.

[@MrRippsalot]

Neat stuff.

[@dr.aliyasirhasan3986]

please what is the value of linear velocity and angular velocity during the welding process?

[@odotcdot85]

We can weld 15mm thick S460/X65 steel with friction stir welding in one pass

[@bjj6708]

I never heard of friction steel welding until this morning, when watching a youtube video of the Orion space capsule, so I found this presentation very edifying, including some well educated comments. Question? can you FSW a piece of material in situ, like a car panel or must the material be clamped down? can you FSW 2 disimmilar materials, eg aluminium and steel? Thanks for posting :-)😀

[@EmpyreanLightASMR]

Yes, I'm listening to a 2014 StarTalk podcast episode (it's slow going; it's a prolific podcast haha) and Bill Nye mentioned SpaceX using this when building rockets. Never heard of it, so here I am. Very cool. I don't understand how the friction is applied by a tool that doesn't itself meld with the metal though maybe this has to do with the rotational speed.

[@juandilasagofficial]

Friction welding works only on flat surface

[@andrewk8636]

Maybe they can use cone shapes for 90° welds

[@dsbupadrasta2385]

Good explanation

[@joebledsoe257]

Uh stir welding was used on the SR71??

[@limalshaji6788]

Amazing

[@puttashyam915]

thank you sir for this video

[@DimMakTen31]

Id love to see hobblw it could be used to repair Aluminum engine blocks. Or to strengthen around the wrist pin journal of performance piston

[@aguilayserpiente]

My muffler's heat shield keeps vibrating loose. Please magic bond it for me.

[@hassanjavedhassanjaved5681]

How we per chased what is the source where we perchased

[@andrewallen9993]

Another great British invention.

[@keissetje]

Well to be fair, friction welding still uses heat to meld items together, It's just that the heat comes from friction instead of an external heat source

[@daa3417]

No the material DOES NOT melt

[@keissetje]

@@daa3417 I stand corrected, thanks for learning me something new 🙂

[@mihailfelixdumitresc]

It is just a version of fretting.

[@MANOJKUMAR-io2zu]

Currently iam doing my final year engineering project on FSW .

[@abhishekkumar55111]

For aluminum to aluminium: 800 to 1200 rpm and high speed steel tool. If steel involved: (don't know) rpm and boron nitride coated tool.

[@abhishekkumar55111]

You need plates to be tightly attached with pressure applied during fsw. Pin dia and depth of penetration is also a factor.

[@ShivaKumar-hh1ko]

@Mescalinum Sunshine you please try with a vertical milling machine... You can find better results...

[@ShivaKumar-hh1ko]

@Mescalinum Sunshine Working of FSW and Milling machine are same.. The thing is we need a tool.. If so you can try... Myself using FSW...

[@arindambaruah5419]

Working on joining Al-6061 and Mg AZ-31.

[@snitox]

I wonder which is stronger... friction weld(where both of the parts melt and conjoin into one part) or friction stir weld.

[@ShivaKumar-hh1ko]

For this particular case they are not using cylindrical rather they are using flat plates...

[@arindambaruah5419]

Very different applications for both. You can't friction stir weld two cylinders. Neither can you friction butt weld two flat plates.

[@adamcurrent2865]

It doesn't seem like it would penetrate that good and are you allowed to use filler?.

[@vipupandit3832]

Is it possible for 0.8 mm sheet joining with the help for butt joint.

[@gaurangjoshi5478]

it is possible

[@salesnorthharbour1454]

She said it was invented in the 90's - it wasn't, she said there's no melting, but surely the heat which causes the plasticisation is actually melting the material? Then she said 'now the materials are welded together', it's not welding is it?

[@stepanadrian]

came here from Jeff Bezos: Amazon and Blue Origin | Lex Fridman Podcast

[@christophermadsen3333]

Maybe a super stupid question, but could this be used for other materials too? E.g. Carbon Fiber?

[@tristenturner832]

yes it works on other materials, but not on every material. things like carbon fiber would not be a likely candidate due to 2 problems. first is the epoxy doesnt soften when heated, it breaks down, and second is the carbon fibers them selves would not be left in a good weave for the part to have strength. you could think of it like trying to join two T-shirts together with a spinning drill bit. the threads are more likely to wrap around the head and tear off than weave into a strong pattern.

[@sriyanto7099]

I have journal pliss

[@AdamZMouchnic]

Life is good'

[@ranchdressing1037]

"This existed before, but it wasn't patented.. so we patented it."

[@michaelnewman89]

I wanna see you do it to some mild steel .

[@fomalhaut86]

With a carbide tool perhaps? :)

[@mrpanda2655]

fomalhaut86 carbide is hard it would fracture to bits if used for that

[@paintfreek1357]

They have done it, I dosnt read what tool they used. But toy could legally get away with something like tungston, or tungston carbide.

[@raydon1005]

Mishra looks baked AF 😂

[@sumantasamrat7291]

He is an indian n a brahmin lve u sir from india

[@bharatgattu6115]

He may be a brahmin by birth but most probably converted to shudhra with age... love him a loott from everywhere...

[@tg4ever923]

10q for This... 2morrow v have sem exam...😋😋

[@OperationAllOut]

Similar to ultrasonic welding

[@augnkn93043]

No.

[@CEMENTHE4D]

so only in aluminum? didnt see any steel examples, plus brings the aluminum temper to 0. need to re treat the material after to bring it back to a T6 or its soft af and junk. unless used for art.

[@johnmiller7356]

He was working for the university, getting paid and the university paid for the equipment. Why wasn't the university issued the patent?

[@Tacdelio]

cause the university is paying HIM to think for THEM.

[@bharatgattu6115]

If only this researcher could find new way to explore and use FSP and FSW to weld upper and lower vermillion border of this researcher's anatomy it would be amazing for development of FSP and FSW..!!

[@raycarrara8264]

When you weld, bend, brake, or machine a piece of metal it creates a discontinuity. An example of this is creating a weld in a piece of steel. This will change the molecular structure of the steel perhaps making it martensitic. The result of this will be a harder and perhaps stronger piece of steel. This will also result in a steel that is less ductile (not as tough). The same is true when you brake a piece of steel. It will be harder and more rigid at the brake line however if it is struck by something it will crack rather than bend (result, less ductile or not as tough). Can someone please tell me how the molecular structure of metal that is friction stir welded is changed? Is the result both more ductile and stronger? If this is the result, it would be an amazing process. For every give there is a take. For every advantage there is a disadvantage. If this process defies the rules of the last two sentences the possibilities are limitless.

[@AB-ho1lt]

How the hell can you use the word "martensitic" talking about Aluminium

[@Dr.Ing.WaseemAmin]

Yes, the weldment is stronger and tougher since there are no molecules in metals rather there are metallic bonds... the crystals are broken down into finer crystals during this solid-state welding process due to plastification driven by FSW tool (frictional heat+extrusion type load), and the resulting fine microstructure gives good resistance to slip hence strength is improved as well as favours ductility once slip is initiated. Martensite is a diffusionless transformation which is driven by a certain amount of cooling rate (observed in certain materials e.g. NiTinol, High entropy alloys including steels).

[@sandipborade9897]

Is this technology create a noise????

[@gadlicht4627]

Anything rubbing two or more things together rapidly will make a lot of noise as it will cause vibrations. Vibrations = noise

[@jaxturner7288]

Sandip Borade probably silent.

[@frankduncan5685]

The loudest noise is from the machine, not the tool. You can stand next to it and hold a conversation in a normal voice.

[@vikas2435]

Indian

[@gb5uq]

Invented in 1991?. I worked for a company manufacturing engine valves using friction welding in 1972

[@odotcdot85]

It's friction stir welding and not friction welding. The processes are different

[@alexlo7708]

Electron beam welding are superior today.

[@constantinosschinas4503]

the innovation shown here is using a welding technique in non-welding applications, such as enhancing metal properties.

[@hatemmohamed3933]

Any one can translate this video into arabic

[@toomvip8380]

Yes I can

[@hatemmohamed3933]

Ohhhhhh You are my hero 💗

[@gulabtokas8232]

Who is here after working for SpaceX?

[@billy-joes6851]

Yup lol

[@Harshgupta-bu6jl]

He is an Indian proud

[@Fylnnn]

He's from Indian "descendants", himself was american lmfao

[@JM-yx1lm]

This isn't that good because of the canal that is left after the process. At least with traditional welding, I can grind off the top of the weld to reveal a finished weld that cannot be seen.

[@abm8017]

Some alloys like AL 7075t6 would not have traditional welding work, that's why this method is used in spacecraft manufacturing

[@arindambaruah5419]

Tough to weld low melting point light weight alloys such as Al and Mg using conventional techniques. Hence, FSW's importance has grown.

[@user-rh9uy9uy5i]

ko

[@m.h.9597]

Wow Texas University and you think its India...

[@JRA8800]

Who is here after reading Elon Musk’s biography? (page288)🤓

[@soorkie]

Yaay

[@Ali.g.97]

I refuse to believe this primitive method of bonding metal isn't porous as hell

[@mikeokota6022]

Immigrants

[@godbluffvdgg]

smh...These people that make videos like this and then dumb them down...~ stupid girl voice~ "friction; like when you rub your hands together to get them warm"....The following is not yelling; just an emphasized statement...WE KNOW WHAT FRICTION IS; IF WE'RE INTERESTED IN WELDING; OR VIDEOS CONCERNING FRICTION WELDING AND MOST OF US HAVE SEEN TRAIN WHEELS DONE BY FRICTION YEARS AGO! ...Just sayin...

[@Deathrape2001]

LOL stands there like a robot =)) This is not how U $ell product =)) Need 2 B enthusiastic & human, & using the arms hands 2 show stuff, not just 'read a script'. Imagine a movie with actors just standing in place always with no style 2 it, just reading lines = boring =P

[@michaelexman5474]

molecules you can weld molecules you cant weld atoms

[@rasmusandersen2007]

All thiese lies... It's NOT stronger than a correct weld.. it's NOT as hard as normal aluminium It's NOT the same as a complete sheet of aluminium. lies lies lies...

[@greatsiraj]

dude FSW have higher weld strength also dissimilar metals can be welded with no fumes and smoke.Yield strength and Tensile strength of friction stir welding joints are 31% and 13% higher than that of TIG welded joints. and TIG is stronger than MIG weld but MIG is more accurate.

[@rasmusandersen2007]

@@greatsiraj I just t old what was the lies.. idc about what it can do.. its NEVER going to be stronger when heated and cooled again in only 1 part of the sheet.

[@jimwolabaugh3608]

Rasmus Andersen... You must’ve been one of his students that couldn’t make the grade... And still bitter about it. From what I know about welding and metallurgy, this seems to be a much better and more efficient way of welding aluminum. When a HAZ is created by welding, there is more margin for error. This method creates less heat. Seems pretty cut and dry

[@ljubomirculibrk4097]

@Mescalinum Sunshine Russians heat treat intire Mig29/35 central body (aluminium fuel cell welded together) to gain a part of mech strenght lost due to welding. Whit FSW there is no need for that, plus you can weld in positions whit cnc weldind precision. Its used for cryo fuel rocket tanks, if thats a sighn of something good.

[@thestumaji656]

@@greatsiraj I'm going to have to argue that GTAW (tig) is FAR more accurate than GMAW (mig) and i am certified AWS D17.1 the only problem i can see is will FSW have 100% penetration? I don't think it will whill leave weak spots in the weld.