FSW Welding of Aluminium Casting Alloys

Journal title

Archives of Foundry Engineering




No 2

Publication authors


Product development ; Casting defect ; FSW ; Aluminium

Divisions of PAS

Nauki Techniczne


Archives of Foundry Engineering continues the publishing activity started by Foundry Commission of the Polish Academy of Sciences (PAN) in Katowice in 1978. The initiator of it was the first Chairman Professor Dr Eng. Wacław Sakwa – Corresponding Member of PAN, Honorary Doctor of Czestochowa University of Technology and Silesian University of Technology. This periodical first name was „Solidification of Metals and Alloys” , and made possible to publish the results of works achieved in the field of the Basic Problems Research Cooperation. The subject of publications was related to the title of the periodical and concerned widely understand problems of metals and alloys crystallization in a casting mold. In 1978-2000 the 44 issues have been published. Since 2001 the Foundry Commission has had patronage of the annually published “Archives of Foundry” and since 2007 quarterly published “Archives of Foundry Engineering”. Thematic scope includes scientific issues of foundry industry:

  • Theoretical Aspects of Casting Processes,
  • Innovative Foundry Technologies and Materials,
  • Foundry Processes Computer Aiding,
  • Mechanization, Automation and Robotics in Foundry,
  • Transport Systems in Foundry,
  • Castings Quality Management,
  • Environmental Protection.


The article contains basic information associated with the impact of the FSW process parameters on the forming of a weld while friction

welding of aluminium casting alloys. Research was conducted using specially made samples containing a rod of casting alloy mounted in

the wrought alloy in the selected area of FSW tool acting. Research has thrown light on the process of joining materials of significantly

dissimilar physical properties, such as casting alloys and wrought alloys. Metallographic testing of a weld area has revealed the big impact

of welding conditions, especially tool rotational speed, on the degree of metal stirring, grain refinement and shape factor of a weld. As the

result of research it has been stated that at the high tool rotational speed, the metals stirring in a weld is significantly greater than in case of

welding at low rotational speeds, however this fails to influence the strength of a weld. Plastic strain occurring while welding causes very

high refinement of particles in the tested area and changing of their shape towards particles being more equiaxial. In the properly selected

welding conditions it is possible to obtain joints of correct and repeatable structure, however in the case of the accumulation of cavities in

the casting alloy the FSW process not always eliminates them.


The Katowice Branch of the Polish Academy of Sciences




Artykuły / Articles


ISSN 2299-2944