Friction Stir Welding of Steels

Friction Stir Welding of Steels

1st Edition - February 1, 2023

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  • Authors: Koteswararao Rajulapati, K. Bhanu Rao, G. Madhusudhan Reddy, Suresh Meshram
  • Paperback ISBN: 9780323857604

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Friction stir welding (FSW) has emerged as an alternative and a promising technique to join several engineering materials, especially similar/dissimilar types. Although FSW has been extensively investigated at the laboratory level with industrial products produced for various alloys of Aluminum, its usage in the fabrication of steel components has not been broadly explored. Friction Stir Welding of Steels: Science, Engineering and Technology will present the use of FSW process on thick sectioned Ferritic-Martensitic steels whose success is credited to the use of advanced tool designs, tool materials, proper choice of heat input parameters, traverse speeds and in-line monitoring of temperature rise at the tool/sample interface. It covers all these unique aspects pertaining to FSW of different classes steels and their applications including: high strength Bainitic steels for automotive applications; maraging steels for space and missile applications; the variation in microstructure and mechanical properties; austenitic stainless steels; and chemical plants (Pipe steels).

Key Features

  • Discusses problems associated with joining of steels using traditional fusion welding techniques and proposing FSW as an alternative
  • Reviews the criteria for selection of tool material (s)
  • Previews the optimization of process parameters, including technical recommendations


Researchers, materials processing engineers, design engineers, welding engineers, machining engineers and students

Table of Contents

  • 1. Introduction and need for writing this book
    2. Physical metallurgy of steels
    3. Key problems associated with fusion welding techniques for steels
    4. FSW as an alternative to fusion welding methods
    5. Adaption of FSW for harder materials such as steels and associated problems
    6. Choice of FSW parameters, tool materials for steels and their optimization
    7. Metallurgical aspects of FSW of steel
    8. FSW of harder and thicker steel plates
    9. Conclusions

Product details

  • No. of pages: 160
  • Language: English
  • Copyright: © Butterworth-Heinemann 2023
  • Published: February 1, 2023
  • Imprint: Butterworth-Heinemann
  • Paperback ISBN: 9780323857604

About the Authors

Koteswararao Rajulapati

Dr. Koteswararao V. Rajulapati is a Professor in the Department of Engineering Sciences and Technology at the University of Hyderabad , India. He received his Ph.D. in Materials Science and Engineering from North Carolina State University. .His research interests include friction stir welding/processing, nanostructured materials, nanoindentation and deformation behaviour in small volumes, high entropy alloys, bulk deformation behaviour. He serves as an editorial board member and reviewer of several international reputed journals.

Affiliations and Expertise

Professor, University of Hyderabad, Hyderabad, India

K. Bhanu Rao

Dr. K. Bhanu Sankara Rao FASM, FNAE, FIIM, FASc, is currently the Pratt and Whitney Chair Professor at the University of Hyderabad. During Dr. Rao’s more than forty-year career he has held a number of prestigious positions including serving as the Ministry of Steel Chair/ Professor and the Dean of the School of Engineering Sciences and Technology at the University of Hyderabad. He received his Ph.D in Metallurgical Engineering from the University of Madras. His current research interests include Mechanical Metallurgy, Physical Metallurgy, Welding Science and Technology and Powder Metallurgy. He has published over 250 research papers and has served as an Editor of International Materials Reviews, International Review Board Member of Metallurgical and Materials Transactions and Materials Engineering and Performance. He is a member of Technical Books Committee of ASM International. He has been the recipient of Best Metallurgist Award from Ministry of Steel (1995), MRSI Medal (1997), NASA Appreciation (1994), BinaniGold Medal of IIM (1990), SAIL Gold Medal (Certificate of Merit) of IIM (2000),I.T. Mirchandani (1990), H.D. Govindaraj (1990), Nucor (1996), and D&H Schechron(1994) Awards of the Indian Institute of Welding.

Affiliations and Expertise

Pratt and Whitney Chair, University of Hyderabad, Hyderabad, India

G. Madhusudhan Reddy

Dr. G. Madhusudhan Reddy (Director, Defence Metallurgical Research Laboratory, Hyderabad) obtained his bachelor’s degree in Mechanical Engineering with distinction from Kakatiya University in 1985, he completed his master’s degree with Honors from Indian Institute of Technology, Roorkee in 1987. He started his carrier as a Scientist in 1987 at the Combat Vehicles R&D Establishment (CVRDE), Chennai. He was transferred to the Defence Metallurgical Research Laboratory (DMRL), Hyderabad in 1989. Having acquired significant hands on experience in welding research at DMRL, Hyderabad, He then embarked on focused research in the welding of Aluminum-Lithium alloys for his Doctoral degree at the Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai. Dr. Reddy‘s career spanning nearly 32 years is marked by significant R&D contributions in the field of materials joining and surfacing and have been direct applications in defence and aerospace technologies. Dr. Reddy is very well known internationally for his excellence in the field of friction-stir welding of very large components required by aerospace programs in India. he has been elected Fellow of American Society of Metals, Indian National Academy of Engineering and Telangana Academy of Sciences, Andhra Pradesh Academy of Sciences, Indian Institute of Metals, Indian Institute of Welding, and Indian Welding Society. He has published more than 260 research papers in referred journals and equal number in conference proceedings apart from possessing several patents to his credit.

Affiliations and Expertise

Director, Defence Metallurgical Resesearch Lab, Hyderabad, India

Suresh Meshram

Dr. Suresh D. Meshram joined as a scientist with the Defence Metallurgical Research Laboratory, Hyderabad, India in 2003. Since then his worked has been focused in the area of friction and friction stir welding (FSW) of metallic materials, including the effect of process parameters on material flow behaviour, weld microstructure, mechanical properties and their correlation. The main emphasis of the work is on joining of thick and high strength materials using FSW process. These high strength materials that are welded and studied using FSW process mainly includes maraging steel (ultra-high strength material), nickel base super alloy and titanium alloys. He has authored peer-reviewed international papers and technical reports, as well as several national and international conference papers on friction and FSW welding of metallic material.

Affiliations and Expertise

Scientist, Defence Metallurgical Research Lab, Hyderabad, India

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