This study presents a comparative investigation of both Gas Tungsten Arc Welding (GTAW)
and Friction Stir Welding (FSW) techniques for welding SAF 2507 super duplex stainless
steel plates. Both fusion and solid-state welding methods are widely utilized in the metal
fabrication industry, each offering distinct advantages and limitations. FSW, recognized as
a promising solid-state welding approach, is assessed alongside GTAW to validate its efficacy
concerning power consumption and weld quality. The welded joints on 6 mm-thick SAF 2507
super duplex stainless steel plates, commonly used in power stations and petroleum service
companies, were examined. Additionally, the viability of FSW as a groove filling welding
technique was explored. Tungsten carbide tools are utilized to produce butt-joints under
specified parameters (applied load 15 KN, rotation speed of 400 rpm, transverse speed 25
mm/min, tilt angle 3 degrees). For comparison, the same SDSS plates were welded using gas
tungsten arc welding (GTAW). The joints produced using a 60-degree V-shape groove with
a 2 mm root face were examined and characterized using visual inspection, radiographic test,
liquid penetrant test, hardness test, and tensile test. The results indicate that FSW was used
successfully to weld SDSS joints with a groove-like defect. The comparison aimed to
determine which of these welding techniques consumes less energy and produces sound
joints. FSW was found to consume less energy and produce better mechanical properties in
the weld zone.