Paper Titles

Enhancing the Bonding of Insulated Homogeneous Interfaces in Factory Joints via Ultrasonic Vibration
p.1

Development of a Novel Rivet-Based Joining-By-Forming Process Using Flat Dies
p.9

Influence of Tumbling-Induced Geometric Anisotropy on the Mechanical Performance of Self-Piercing Rivet Joints
p.19

Experimental and Numerical Evaluation of L-PBF Printed Tool for Friction Stir Welding
p.29

Micro Friction Stir Spot Welding for Copper Current Collector Applications - An Experimental Study
p.41

Influences of the Rolling Parameters on Multi-Material Copper-Aluminum Composites via Compound Casting
p.55

A Hybrid Joining Strategy for Al–Cu Bimetallic Sheets Produced by Friction Stir Welding
p.69

Potentials of Heat Superimposed Rotary Friction Welding for Steel-Aluminium Joints
p.77

HomeMaterials Science ForumMaterials Science Forum Vol. 1185Experimental and Numerical Evaluation of L-PBF...

Experimental and Numerical Evaluation of L-PBF Printed Tool for Friction Stir Welding

Article Preview

View Pdf By email

Abstract:

In Friction Stir Welding (FSW) tool geometry plays a critical role in governing heat generation, material flow, and microstructural evolution within the weld. In this study, the feasibility and performance of FSW tools manufactured by Laser Powder Bed Fusion (L-PBF) are experimentally and numerically investigated. A non-conventional FSW tool produced in AISI 316L by L-PBF was designed and compared with a conventional machined steel tool in the welding of AA6082-T6 sheets performed using already optimized process parameters. This was followed by tensile testing and macro-and micro-hardness measurements, and a punctual microstructural analysis. In addition, a 3D thermo-mechanical finite element model was employed to forecast and analyze the temperature distribution, the effective strain and the overall material flow. The results show that the tool manufactured using L-PBF enables FSW joints to achieve mechanical properties and welding efficiency similar to those of the standard tool. Finite Elements Models (FEM), in good agreement with experimental results, show that the geometry of the additive tool promotes greater plastic deformation and lower peak temperatures, confirming both the validity of the model and the suitability of L-PBF for the advanced design of FSW tools.

You have full access to the following eBook

Innovative Joining by Forming

Info:

Periodical:

Materials Science Forum (Volume 1185)

Pages:

29-39

DOI:

https://doi.org/10.4028/p-hr6sOv

Citation:

Cite this paper

Online since:

April 2026

Authors:

Marco Zambelli*, Sara Bocchi, Marco Negozio, Gianluca Danilo D'Urso, Claudio Giardini, Laura Antonini

Keywords:

AA6082, Additive Manufacturing, Friction Stir Welding, L-PBF, Tool Geometry

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

Share:

Citation:

* - Corresponding Author

[1] M.I.A. Habba, M.M.Z. Ahmed, Friction stir welding-based technologies: A comprehensive review from the sustainable manufacturing perspectives, Journal of Materials Research and Technology, 38 (2025) 1–29.

DOI: 10.1016/j.jmrt.2025.07.184

[2] Neeru Bhardaj, Uday Dixit, et al., Recent Developments in Friction Stir Welding and Resulting Industrial Practices, Research Gate, (2019).

[3] B. Yelamasetti, M. Sridevi, N.S. Sree, N.K. Geetha, P. Bridjesh, S.D. Shelare, C. Prakash, Comparative Studies on Mechanical Properties and Microstructural Changes of AA5052 and AA6082 Dissimilar Weldments Developed by TIG, MIG, and FSW Techniques, Journal of Materials Engineering and Performance 2024 34:11, 34 (2024) 9972–9985.

DOI: 10.1007/s11665-024-09867-9

[4] A.P. Reddy, S. Dewangan, A COMPARATIVE ANALYSIS AMONG THE WELDED Al-6061 PLATES JOINED BY FSW, MIG AND TIG WELDING METHODS, 29 (2023) 75–81.

DOI: 10.36547/ams.29.2.1778

[5] S. Sambasivam, N. Gupta, A. saeed jassim, D. Pratap Singh, S. Kumar, J.M. Giri, M. Gupta, A review paper of FSW on dissimilar materials using aluminum, Mater Today Proc, (2023).

DOI: 10.1016/j.matpr.2023.03.304

[6] S. Mabuwa, V. Msomi, Review on Friction Stir Processed TIG and Friction Stir Welded Dissimilar Alloy Joints, Metals 2020, Vol. 10, Page 142, 10 (2020) 142.

DOI: 10.3390/met10010142

[7] Aydın ŞIK, M. Önder, Comparison between mechanical properties and joint performance of AA 2024-O aluminium alloy welded by friction stir welding and TIG processes, Kovove Materialy-Metallic Materials, (2012).

DOI: 10.4149/km_2012_2_131

[8] U. Dwivedi, S. Tiwari, A. Mishra, S. Das, Comparative Study of Weld Characteristics of Friction Stir Welded Joints on Aluminium 7075 with Autogenous TIG, Mater Today Proc, 22 (2020) 2532–2538.

DOI: 10.1016/j.matpr.2020.03.382

[9] Evaluation of Friction Stir Weld Process and Properties for Aircraft Applications, 2018.

[10] TWI - Designs and Materials of Friction Stir Welding Tools, (2024).

[11] Y.N. Zhang, X. Cao, S. Larose, P. Wanjara, Review of tools for friction stir welding and processing, Canadian Metallurgical Quarterly, 51 (2012) 250–261.

DOI: 10.1179/1879139512y.0000000015

[12] M. Xing, H. Wang, Z. Zhao, H. Lu, C. Liu, L. Lin, M. Wang, X. Song, Additive manufacturing of cemented carbides inserts with high mechanical performance, Materials Science and Engineering: A, 861 (2022) 144350.

DOI: 10.1016/j.msea.2022.144350

[13] Victor Lubkowitz, Nitin Reothia, Frederik Zanger, Enhancement of groove turning performance by additively manufactured tool holders with internal cooling channels and combined cooling strategies, 21st Machining Innovations Conference for Aerospace Industry 2021, (2021).

DOI: 10.2139/ssrn.3922719

[14] M. Seyam, P. Koshy, M. Elbestawi, Laser powder bed fusion of WC-Co form turning tools with integrated cooling features: Design, printing, and test machining of Ti6Al4V, CIRP Annals, 73 (2024) 65–68.

DOI: 10.1016/j.cirp.2024.04.053

[15] S. Gruber, C. Grunert, M. Riede, E. López, A. Marquardt, F. Brueckner, C. Leyens, Comparison of dimensional accuracy and tolerances of powder bed based and nozzle based additive manufacturing processes, J Laser Appl, 32 (2020) 32016.

DOI: 10.2351/7.0000115

[16] A. Alshami, A. Shuaib, A. Mayyas, Evaluation of the properties of experimental friction stir welding pin tools consolidated from W-25 wt% Re alloy using laser powder bed fusion (LPBF) process, Manuf Lett, 44 (2025) 1038–1043.

DOI: 10.1016/j.mfglet.2025.06.123

[17] M. Seyam, P. Koshy, M. Elbestawi, Laser powder bed fusion of WC-Co form turning tools with integrated cooling features: Design, printing, and test machining of Ti6Al4V, CIRP Annals, 73 (2024) 65–68.

DOI: 10.1016/j.cirp.2024.04.053

[18] S. Bocchi, M. Negozio, Experimental Investigation and Finite Element Simulation of the Microstructural Evolution in AA6082 Friction Stir Welded Joints, J Mater Eng Perform, 34 (2025) 11274–11291.

DOI: 10.1007/s11665-025-10752-2

[19] S. Bocchi, G. D'Urso, C. Giardini, The effect of heat generated on mechanical properties of friction stir welded aluminum alloys, The International Journal of Advanced Manufacturing Technology, 112 (2021) 1513–1528.

DOI: 10.1007/s00170-020-06462-9

[20] S. Bocchi, G. D'Urso, C. Giardini, Influence of copper interlayer on the mechanical performance of friction stir welded AA2024, International Journal of Advanced Manufacturing Technology, 133 (2024) 5811–5828.

DOI: 10.1007/s00170-024-14106-5

[21] S. Bocchi, G. D'urso, C. Giardini, Preliminary study of the mechanical characteristics implementation of friction stir welded AA2024 joints by adding pure copper, Materials Research Proceedings, 25 (2023) 213–220.

DOI: 10.21741/9781644902417-27

[22] M. Quarto, S. Bocchi, G. D', N.A. Urso, C. Giardini, Hybrid finite elements method-artificial neural network approach for hardness prediction of AA6082 friction stir welded joints, International Journal of Mechatronics and Manufacturing Systems, 15 (2022) 149.

DOI: 10.1504/ijmms.2022.124919

[23] S. Bocchi, M. Negozio, Experimental Investigation and Finite Element Simulation of the Microstructural Evolution in AA6082 Friction Stir Welded Joints, (n.d.).

DOI: 10.1007/s11665-025-10752-2