Friction Stir Welding Calculator
Calculate FSW parameters for solid-state joining of metals.
Typical FSW Parameters by Material
| Material | RPM Range | Traverse (mm/min) |
|---|---|---|
| Al 6xxx | 800-1500 | 100-500 |
| Al 2xxx/7xxx | 600-1200 | 80-400 |
| Copper | 400-800 | 50-200 |
| Steel | 200-600 | 50-200 |
| Titanium | 100-400 | 25-100 |
Understanding Friction Stir Welding
Key Process Parameters
FSW quality depends on the balance between rotation speed (heat input), traverse rate (weld time), and axial force (material flow). The "hot" vs "cold" weld concept refers to this balance.
Tool Design Principles
- Shoulder: Generates ~80% of heat, contains material, typically 2.5-3x material thickness
- Pin: Stirs material, creates mixing, typically 0.9x material thickness for full penetration
- Shoulder/Pin Ratio: Typically 2.5-3.5:1 for optimal material flow
- Pin Features: Threads, flats, or flutes improve material flow
Defects and Causes
- Tunnel Defect: Too cold - increase RPM or decrease traverse
- Surface Galling: Too hot - decrease RPM or increase traverse
- Root Defect: Insufficient penetration - increase pin length or force
- Flash: Excessive heat - reduce force or RPM