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Introduction to Friction Stir Welding (FSW) - NASA

Introduction to Friction stir Welding (FSW) Bob Carter NASA Glenn Research Center Advanced Metallics Branch Agenda Short History of Aluminum Welding at NASA FSW Background and Applications Conventional FSW Self Reacting FSW Advantages and Disadvantages Microstructure and Avoidable Defects Specifications and Non Destructive Evaluation Process Variants Equipment and Tooling A lifetime in rocketry has convinced me that Welding is one of the most critical aspects of the whole job!! Dr. Wernher von Braun. 2 Short History of Aluminum Welding at NASA Late 1950 s Early 1970 s (Explorer 1, Mercury, Gemini, Saturn) Welding of aluminum alloys in its infancy Jupiter, Redstone, Saturn I, and Saturn V welded using Gas Metal Arc Welding (GMAW) and Gas Tungsten Arc Welding (GTAW) Horizontal Welding of tank structures led to significant Welding problems.

Milling machine spindles are not designed to endure the radial and thrust loads encountered during FSW. Milling machines do not offer load control or load monitoring.

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