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<p>Friction stir welding tools are conventionally manufactured using wrought H13 tool steel, which is prone to significant wear and degradation during prolonged industrial use, leading to poor weld performance and reduced tool life. To address these challenges, this study explores fabrication of an industrial-grade friction stir welding tool using wire + arc additive manufacturing process. Objective is to enhance welding tool performance through optimizing material usage, hardness, and microstructural properties. Fabricated tool achieved an average hardness of 52 HRC, which further increased to 59 HRC following heat treatment significantly higher than the 44 HRC observed in conventionally wrought H13 steel. These improvements are attributed to refined microstructure developed through adapted fabrication process and post-deposition treatment. Enhanced hardness directly correlates with improved wear resistance and service life, making fabricated tool suitable for high-demand industrial friction stir welding tool application. This study demonstrates feasibility of wire + arc additive manufacturing as a sustainable and high-performance manufacturing route for next-generation welding tools.</p>

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Fabrication of a Novel Industrial Friction Stir Welding Tool through Wire + Arc Additive Manufacturing for Joining Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2025年8月11日

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  • Dhinakaran Veeman,
  • Vijayakumar Murugesan Devarajan,
  • Suresh Arunachalam,
  • Muthukumaran Arjunan,
  • Mohith Mohan Das,
  • Kanishkaa Jeevaraj,
  • Pechimuthu Arumugaperumal,
  • Mohan Kumar Subramaniyan

摘要

Friction stir welding tools are conventionally manufactured using wrought H13 tool steel, which is prone to significant wear and degradation during prolonged industrial use, leading to poor weld performance and reduced tool life. To address these challenges, this study explores fabrication of an industrial-grade friction stir welding tool using wire + arc additive manufacturing process. Objective is to enhance welding tool performance through optimizing material usage, hardness, and microstructural properties. Fabricated tool achieved an average hardness of 52 HRC, which further increased to 59 HRC following heat treatment significantly higher than the 44 HRC observed in conventionally wrought H13 steel. These improvements are attributed to refined microstructure developed through adapted fabrication process and post-deposition treatment. Enhanced hardness directly correlates with improved wear resistance and service life, making fabricated tool suitable for high-demand industrial friction stir welding tool application. This study demonstrates feasibility of wire + arc additive manufacturing as a sustainable and high-performance manufacturing route for next-generation welding tools.