TWI

An overview is presented of the twenty year history and technological developments relating to the application of friction stir welding (FSW) to aluminium alloy railway car body shells. Issues discussed include the history of railway car body shell structures, problems with conventional arc welding methods, the benefits of FSW (e.g. reduction of deformation, low porosity weldments, alloy homogenisation at joints and less hazardous work environment), technical problems (such as limited allowable gap, exit holes and undercut at the joining line), single skin car body shells, quality control (hardness distribution and fatigue tests), double skin car body shells, stress distribution and fatigue strength in FSW joints, door frames, and robotic FSW equipment.

11th International Symposium, 17-19 May 2016, Session 2A: Applications I, Paper 02