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Self-reacting friction stir welding (SR-FSW), also called bobbin-tool friction stir welding (BT-FSW), is a solid state welding process similar to friction stir welding (FSW) except that the tool has two opposing shoulders instead of the shoulder and a backing plate found in FSW. The tool configuration results in greater heat input and a symmetrical weld macrostructure. A significant amount of information has been published in the literature concerning traditional FSW while little has been published about SR-FSW. An optimization experiment was performed using a factorial design to evaluate the effect of process parameters on the weld temperature, surface and internal quality, and mechanical properties of self-reacting friction stir welded aluminum alloy 6061-T6 butt joints. The parameters evaluated were tool rotational speed, traverse speed, and tool plunge force. A correlation between weld temperature, defect formation (specifically galling and void formation), and mechanical properties was found. Optimum parameters were determined for the welding of 8-mm-thick 6061-T6 plate.

Single-walled carbon nanotubes (SWCNTs) were added to aluminium using friction stir processing (FSP). The SWCNTs survived the thermal and stress cycles involved with friction stir processing. The Raman spectroscopy and SEM results are presented. Potential applications of nanotubes inserted into metals by this method are discussed.