Feasibility of Deep Crack Repair Using a Novel Friction Stir Chip Welding Process

Document Type : Research Paper

Authors

1 Department of Mechanical Engineering, University of Birjand, Birjand, Iran

2 Department of Mechanical Engineering, Azarbaijan Shahid Madani University, Tabriz, Iran

3 Department of Mechanical and Materials Engineering, Birjand University of Technology, Birjand, Iran

Abstract

A new friction stir chip welding (FSCW) method is presented to use waste machining chips for repairing deep cracks. This technique provides an economical solution for industry by reducing landfill waste and minimizing the energy-intensive demand for primary aluminum production. Aluminum 7075 was used to evaluate the feasibility of this method. The crack was removed by an in-depth hole and filled with machining chips, which were subsequently welded using non-consumable tools. The most effective parameter for achieving a proper joint was the input heat, governed by the tool rotational speed and holding time. The effects of these parameters on weld quality, microstructure and hardness across different welding zones were investigated. The results showed that increasing the tool rotational speed and holding time led to higher heat input. The specimen welded at the highest speed and holding time exhibited the greatest hardness and strength. Specimens with a continuous structure demonstrated higher hardness, and vice versa.

Keywords

References

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Iranian Journal of Materials Forming
Volume 13, Issue 1
January 2026
Pages 30-44

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