TWI

The concept and theoretical principles of friction flow welding are presented. Numerical simulation using 'Deform-3D' software was used to compared and optimise the process. The applicability of friction flow welding to different aluminium alloys was evaluated using 2024-T3 AlCu alloy (3 mm thickness) and different types of tool fabricated from H13 tool steel were considered. Results of experimental friction flow spot welding of 2024-T3, 6082-T6 and 7050-T7451 alloys and friction flow butt and lap welding of 2024-T3 alloy are reported. The microstructure, hardness, plastic flow and diffusivity of butt and lap welded joints were examined. The ability of friction flow welding to produce reliable solid state joints through the diffusion of the heat plastic flow of the material generated by the welding tool is discussed. The application of friction flow welding to the repair of surface defects, filling of keyholes and modification of surface performance, especially in the aircraft industry, is considered.

8th International Symposium, 18-20 May 2010, Session 9B: FSP and Derivatives, Paper 04