TWI

The decision to use friction stir welding (FSW) in the manufacture of aluminium alloy car wheels by Simmons Wheels, Sydney, Australia is described. Rim sections are formed from alloy 6061 in thicknesses of 4-6 mm. These are attached to cast or forged centre discs. The manufacturing system was based on buying 6061 alloy in coiled sheet, cutting off accurate lengths of sheet, rolling the cut length into a cylinder, seam welding the cylinder using FSW and spinning the bands into rims on a spinning lathe. Production experience is described, with reference to early problems involving heat treatment. Using FSW, overall rim material yields have been increased from 65 to 95%. Reliability of FSW-based rims is higher than for rims spun from discs.

3rd International Symposium, 27-28 Sep 2001, Session 7: Properties & Performance, Paper 02