Friction Stir Welding Lab

Award Received by a Student of FSW Lab:

Mr. Himal Agrawal [13MF10010] participated for world-wide “ASME IDSC (Innovative Design Simulation Challenge)-2016” at Charlotte, North Carolina, USA on August 21, 2016. He has won in the category of “Best Utility in Commercial Software” for his work on “A Thermo-mechanical coupled simulation of friction stir welding with experimental validation”, which he did during 3rd year of BTech, and extended this work for his internship under the supervision of Prof. Surjya K Pal (Dept of Mechanical Engg @ IIT Kharagpur).

CONGRATS to HIMAL

Patent Filed by FSW Lab:

1.Counter Rotating Twin Tool with Variable Gap Setup for Friction Stir Welding (Filed Ref No: 1297/KOL/2014, Date: 15/Dec/2014 )

2. A Counter Rotating Pin and Shoulder Tool Arrangement for Friction Stir Weld System (Filed Ref No: 201631016398, Date: 11/May/2016)

3. Add-on Kit for Doing Cost Effective, Energy Efficient, Rapid, Solid-State Friction Sintering on Vertical Milling/Drilling/Friction Stir Welding Machines (Filed Ref No: 201731037839, Date: 25/Oct/2017).

4. Real time surface defect analysis and correction in friction stir welding process by image processing (Approved by the Institute, and Submitted for filing on May 22, 2018)

5. Cloud based Remote Manufacturing with Machine Learning based Real Time Control (Approved by the Institute, and Submitted for filing on May 22, 2018)

Sponsored Projects @ FSW Lab

DST India funded Project on “FRICTION STIR WELDING OF ALUMINUM AND STEEL SHEET METALS FOR AUTOMOBILE COMPONENTS”, PI: Prof Surjya K. Pal, Co-PI: Prof S B Singh. Duration: 3 years (March 2016 to March 2019). Rs: 44.04 Lakhs.

DHI and TCS funded Project on “REMOTE MONITORING AND REAL TIME CONTROL OF DEFECTS IN FRICITON STIR WELDING PROCESS AND PREVENTIVE HEALTH MONITORING OF FRICTION STIR WELDING MACHINE”, PI: Prof Surjya K. Pal, Co-PI: Prof S Misra. Duration: 5 years from Dec 24, 2017. Rs: 7.49 Crore.

Some Recent Journal publications by FSW Lab:

1. Kumari, K., Pal, S. K., and Singh, S. B., “Friction Stir Welding by using Counter-rotating Twin Tool”, Journal of Material Processing Technology, Volume 215, January 2015, Pages 132–141.

2. Kesharwani, R. K., Panda, S. K., and Pal, S. K., “Multi Objective Optimization of Friction Stir Welding Parameters for Joining of Two Dissimilar Thin Aluminium Sheets”, Procedia Materials Science, Elsevier, Volume 6, 2014, Pages 178–187.

3. Kesharwani, R. K., Panda, S. K., and Pal, S. K., “Experimental Investigations on Formability of Aluminium Tailor Friction Stir Welded Blanks in Deep Drawing Process”, Journal of Materials Engineering and Performance, ASM International, 10.1007/s11665-014-1361-5

4. Kumar, Ujjwal, Yadav Inderjeet, Kumari, Shilpi, Kumari, Kanchan, Kumar, Nitin, Kesharwani, Ramkumar, Jain, Rahul, Kumar, Sachin, Pal, Srikanta, Chakravarthy, Debashish, and Pal, Surjya K., “Defect identification in friction stir welding using discrete wavelet analysis”, Advances in Engineering Software, Elsevier Publication, 2015 (Accepted).

5. Bhat, Nagaraj N., Kumari, Kanchan, Dutta, Samik, Pal, Surjya K., Pal, Srikanta, “Friction Stir Weld Classification by Applying Wavelet Analysis and Support Vector Machine on Weld Surface Images”, Journal of Manufacturing Processes (Elsevier). Accepted on July 05, 2015.

6. Mahto, Raju P., Bhoje, R., Pal, Surjya K., Joshi, Harshadeep Shyamkant,and Das, S., “A study on mechanical properties in friction stir lap welding of AA 6061-T6 and AISI 304“, Material Science and Engineering A, Elsevier Publications. Accepted on November, 2015

7. Ranjan, R., Khan, Aaquib R., Parikh, C., Jain, R., Mahto, R., Pal, Surjya K., Pal, S., and Chakravarthy, D., “Classification and Identification of Surface Defects in Friction Stir Welding : an Image Processing Approach, Journal of Manufacturing Processes, Elsevier Publication, Accepted on March 10, 2016

8. Jain, R., Pal, Surjya K., and Singh, S. B., A study on the variation of forces and temperature in a friction stir welding process: a finite element approach, Journal of Manufacturing Processes, Elsevier Publication, Accepted on April 16, 2016

9. Sahu, Prakash, Pal, Sukhomay, Pal, Surjya K., and Jain, Rahul, “Influence of plate position, tool offset and tool rotational speed on mechanical properties and microstructure of dissimilar Al/Cu friction stir welding joints”, Journal of Material Processing and Technology, Elsevier Publication, 235, 2016, p. 55-67

10. Rahul Jain, Surjya K.Pal, Shiv B. Singh, “Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy”, Modelling of Manufacturing Process, Journal of the Institution of Engineers (India), Springer, Series C, Accepted, 2016

11. Kumari Shilpi, Jain Rahul, Kuar Ujjwal, Yadav Inderjeet, Kumar Nitin, Kumari Kanchan, Kesharwani Ram Kumar, Kumar Sachin, Pal Srikanta, Pal, Surjya K., and Chakravarty Debashish, “Defect identification in friction stir welding using continuous wavelet transform”, Journal of Intelligent Manufacturing, Springer, 2016 (Accepted)

12. Sahu Prakash, Kumari Kanchan, Pal Sukhomay, and Pal Surjya K., “Hybrid fuzzy-grey-Taguchi based multi weld quality optimization of Al/Cu dissimilar friction stir welded joints”, Advances in Manufacturing, Springer, 2016 (Accepted)

13. Jain, R., Pal, Surjya K., and Singh, S. B., “Finite element simulation of pin shape influence on material flow and forces in friction stir welding”, International Journal of Advanced Manufacturing Technology, Springer, Accepted on Feb 22, 2017

14. Kesharwani, R. K., Basak, S., Panda, S. K., and Pal, S. K., “Improvement in Limiting Drawing Ratio of Aluminum Tailored Friction Stir Welded Blanks using Modified Conical Tractrix Die”, Journal of Manufacturing Processes, Springer, (accepted on June 04, 2017)

15. Parikh, C., Ranjan, R., Khan, Aaquib R., Jain, R., Mahto, R., Chakravarthy, D., Pal, S., and Pal, Surjya K., “Volumetric defect analysis in friction stir welding based on three dimensional reconstructed images”, Journal of Manufacturing Processes, Elsevier Publication, Accepted on July 05, 2017.

16. Abhishek Sharma, Vyas Mani Sharma, Sanchit Mewar, Surjya Kanta Pal & Jinu Paul, “Friction stir processing of Al6061-SiC-graphite hybrid surface composites”, Materials and Manufacturing Processes, Taylor & Francis, 33 (7), 795-804, 2017.

17. Jain, R., Kumari, K., Pal, Surjya K., and Singh, S. B., “Counter rotating twin-tool system in friction stir welding process: a simulation study”, Journal of Materials Processing Technology, Elsevier Publication, 255, 121-128, 2018.

18. Sahu, Santosh K., Mishra, Debasish, Mahto, Raju P., Sharma, Vyas M., Pal, Surjya K., Pal, Kamal, Banerjee, Susanta, and Dash, Padmanav; “Friction stir welding of polypropylene sheets”, Engineering Science and Technology, an International Journal, Elsevier Publications, 21, 245-255, 2018.

19. Mahto, R.P., Kumar, R., Pal, Surjya K., and Panda, Susanta K., “A comprehensive study on force, temperature, mechanical properties and micro-structural characterizations in friction stir lap welding of dissimilar materials (AA6061-T6 & AISI304)”, Journal of Manufacturing Processes, Elsevier Publications, 31, 624–639, 2018.

20. Prashant Chauhan, Rahul Jain, Surjya K. Pal, and Shiv B. Singh, “Modeling of defects in friction stir welding using coupled Eulerian and Lagrangian method”, Journal of Manufacturing Processes, Elsevier Publication, Accepted on May 22, 2018.

For details, please click: http://www.facweb.iitkgp.ernet.in/~skpal/?page_id=927

Doctoral Scholars of FSW Lab :: 12

Kanchan Kumari
Supervisor: Prof S K Pal

A novel concept on twin tool in FSW

(Thesis submitted)

Ram Kumar Kesharwani
Supervisor: Prof S K Panda
Co-Supervisor: Prof S K Pal

Formability of friction stir tailor welded blanks
(Thesis submitted & PhD viva is over)

Rahul Jain
Supervisor: Prof S K Pal
Co-Supervisor: Prof S B Singh

FE Modeling of a FSW process

Raju Prasad Mahto
Supervisor: Prof S K Pal

Friction Stir Welding of dissimilar materials.

Vyas Mani Sharma
Supervisor: Prof V Racherla
Co-Supervisor: Prof S K Pal

FSW with Coated Tools

Abhijit Sadhu
Supervisor: Prof A K Nath
Co-Supervisor: Prof S K Pal

Laser Based FSW

Debasish Mishra
Supervisor: Prof S K Pal
Co-Supervisor: Prof D Chakravarty

Digital Image Processing for Defect Identification in FSW

Suryakant Sahu
Supervisor: Prof S K Pal
Co-Supervisor: Prof Prakash Srirangam, WMG UK

Friction Stir Welding of Mg-Steel

Omkar Mypati
Supervisor: Prof S K Pal
Co-Supervisor: Prof Prakash Srirangam, WMG, UK

Micro Friction Stir welding

Md Perwej Iqbal
Supervisor: Prof S K Pal
Co-Supervisor: Dr Parthasarathi Mandal, Univ of Manchester, UK

Multiphysics Modeling & Simulation of Friction Stir Welding of Pipe

Ms Debolina Sen
Supervisor: Prof S K Pal
Co-Supervisor: Prof Sushanta K Panda

FSW of tubular structure

Ms Soumya Sangita Nayak
Supervisor: Prof S K Pal
Co-Supervisor: Prof Prakash Srirangam, WMG, UK

FSW using different tool variants

Junior Research Fellow @ FSW Lab

Pooja Sarkar

BTech : Dibrugarh University

MTech: Jadavpur University

FSW

MTech Students on FSW (Past & Present) : 20 (19+1)
2019 ( Ongoing: 1)
Ranjan Kumar Vishwakarma
2018 ( 3)
Abhishek Singh Thakur	Safal Singh	Ashish Tripathi
2017 (2)
Md Perwej Iqbal		Abhishek Gupta
2016 (4)
Prashant Chauhan	Ravi Kumar Patel	Saurabh Suman
Sanchit Mewar
2015 (3)
Vyas Mani Sharma	Sumit Das	Mohanesh Patole
2014 (2)
Aakah Suvankar Bhowmick		Sunit Kumar Swain
2013 (2)
Deepak Chouhan		Sridhar Iyer
2012 (2)
Ravindra Thube		Mahesh Patil Umakant
2011 (1)
	Randhir Oraon

Photographs of FSW Lab

State-of-the-art Facility Available at FSW Lab

Manual FSW Machine	Instrumented NC Linear FSW Machine

3D CNC 6-Axis FSW Machine(including tube welding)	Piezoelectric Rotating Dynamometer
Sensors: 1. Power Sensor 2. Thermal Imager 3. Infrared Thermometer 4. Acoustic Emission Sensor	Software:Various Finite Element Software for FSW Simulation