Lesson Plan
Course Title: Welding
Session Title: Friction Stir Welding (FSW)
Lesson Duration:
1-2 days
[Lesson length is subjective and will vary from instructor to instructor]
Performance Objective:
Understand the elements of Friction Stir Welding.
Specific Objectives:
Upon completion of this lesson, the learner will be able to:
1. Identify the proper tools and equipment necessary for friction stir welding.
2. Describe the process of friction stir welding.
3. List the benefits of using friction stir welding.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to
the activities may result in the elimination of any or all of the TEKS listed.
Welding:

130.323(c)(2)(A)(B)(C)(D)(E)(F)
…explore academic knowledge and skills required for postsecondary
education;
…identify employers' expectations to foster positive customer satisfaction;
…demonstrate the skills required in the workplace such as interviewing skills,
flexibility, willingness to learn new skills and acquire knowledge, selfdiscipline, self-worth, positive attitude, and integrity in a work situation;
…evaluate personal career goals;
…communicate effectively with others in the workplace to clarify objectives;
and
…demonstrate skills related to health and safety in the workplace, as specified
by appropriate government regulations.

130.323(c)(3)(A)(B)(C)(D)(E)(F)(G)(H)(I)(J)(K)(L)(M)(N)(O)(P)(Q)
…demonstrate effective communication skills with individuals from varied
cultures such as fellow workers, management, and customers;
…demonstrate mathematical skills to estimate costs;
…demonstrate technical writing skills related to work orders;
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…apply accurate readings of measuring devices, both U.S. customary and
metric;
…accurately use an appropriate tool to make measurements;
…compute measurements such as area, surface area, volume, and perimeter;
…determine how changes in dimension affect geometric figures;
…calculate problems using whole numbers, fractions, mixed numbers, and
decimals;
…use a calculator to perform computations;
…perform conversions between fractions and decimals;
…understand the functions of angles;
…apply right triangle relationships using the Pythagorean Theorem;
…understand the parts of a circle;
…identify the most reasonable mathematical solution using estimation;
…use cross-sections of three-dimensional figures to relate to plane figures;
…describe orthographic views of three-dimensional figures; and
…describe isometric views of three-dimensional figures.

130.323(c)(4)(A)(B)(C)
…use welding equipment according to safety standards;
…properly dispose of environmentally hazardous materials used in welding;
and
…use appropriate personal protective equipment as needed to follow safety
measures.

130.323(c)(7)(A)(B)
…evaluate weld inspection processes; and
…analyze welding codes
Interdisciplinary Correlations:
English:
110.42(6) – Reading/word identification/vocabulary development
 110.42(6)(A)(B)
…expand vocabulary development through wide reading, listening, and
discussing;
…rely on context to determine meanings of words…
Instructor/Trainer
References:
American Welding Society (AWS)
Modern Welding (2004)
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Instructional Aids:
1. Friction Stir Welding (FSW) PowerPoint Presentation
2. FSW PowerPoint Presentation Slides
3. FSW PowerPoint Presentation Notes
4. FSW PowerPoint Presentation Handouts
5. FSW Test
6. FSW Test Key
Materials Needed:
Conventional milling machine
Aluminum
Equipment Needed:
Computer & monitor to support PowerPoint
Safety equipment
Learner
The student should provide writing instrument and paper for note-taking.
Introduction
Introduction (LSI Quadrant I):
In the industry of welding, there are many different types of materials joined
together. Friction Stir Welding is relatively new, having been developed in the
late 1980’s and patented in 1991. This means that you cannot do this type of
welding without payment of a fee (although TWI gives special consideration to
schools and universities).
Ask: “Can anyone think of a way this is currently being used? (Have PowerPoint
on to show first screen).” Discuss various answers before telling students
“Formula 1 Racing Cars”.
Outline
Outline (LSI Quadrant II):
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Introduction
List the objectives on the board.
Show the PowerPoint.
I.
FSW
i. defined-
II.
Advantages of FSW
i. Superior welds
ii. Low distortion and shrinkage
iii. Less stress
iv. Energy efficient
v. No fume, porosity, spatter
vi. Great mechanical properties
III.
Disadvantages
i. Cannot make fillet welds or joints requiring
metal deposition
ii. There is a keyhole at the end of the weld
iii. Pieces must be rigidly clamped together
iv. Requires a backing bar
IV.
Process
i. Rotating tool
ii. Central pin/probe
iii. Heats
iv. Plasticizes
v. Move tool along joint
vi. Movement pushes material to the rear, eliminating interface.
V.
Questions?
VI. Guided practice.
VII. Independent practice.
VIII. Review and check for mastery.
IX. Informal assessment
X. Test
Application
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Guided Practice (LSI Quadrant III):
Independent Practice (LSI Quadrant III):
Summary
Review (LSI Quadrants I and IV):
Evaluation
Informal Assessment (LSI Quadrant III):
Formal Assessment (LSI Quadrant III, IV):
Extension/Enrichment (LSI Quadrant IV):
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FSW Quiz
Name:__________________________
1.
True or False
FSW joins different metal from the heat of a rotating tool.
2.
True or False
One of the problems of FSW is inferior welds.
3.
True or False
FSW has strong fumes.
4.
True or False
There is a keyhole at the end of the weld.
5.
True or False
It does not require a backing bar.
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FSW Quiz Key
Name:__________________________
1. True or False
FSW joins different metal from the heat of a rotating tool.
2. True or False
One of the problems of FSW is inferior welds.
3. True or False
FSW has strong fumes.
4. True or False
There is a keyhole at the end of the weld.
5. True or False
It does not require a backing bar.
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