TWI Digital Library

With regard to the fabrication of closure welds for used fuel containers, a series of experiments was undertaken to demonstrate the feasibility of creating defect-free partial penetration welds by friction stir welding (FSW) in A516 Grade 70 steel (…

Friction stir welding was employed to fabricate welded joints in AA 7475-T7351 aluminium alloy plates (thickness 6.35 mm) and the effect of kissing bond defects on fatigue life and other mechanical properties was investigated. Welded test specimens …

An economic analysis was undertaken to compare the costs of onshore and offshore pipeline construction scenarios for welds made using friction stir welding (FSW) and conventional mechanised MIG/MAG welding. Pipe diameters of 1067 and 305 mm were sel…

A hybrid welding system called ultrasound supported friction stir welding was developed to mitigate the strength reducing effects of brittle intermetallic phase layers and was applied to the fabrication of dissimilar joints between wrought aluminium…

Models to predict the precipitate and grain size evolution in AA7449 aluminium alloy friction stir welds are presented and compared with experimental data. Bead on plate welds on 3.2 mm thickness sheets of composition Al, 8.4%Zn, 2.1%Mg, 1.8%Cu were…

A comparative study was undertaken of three different machine types, a modified high payload robot, a CNC milling machine and an ESAB "SuperStir" FSW machine, in terms of their capability for FSW of various aluminium alloys using identical process p…

An experimental investigation was undertaken to examine how tool pin induced material flow and intermetallic growth conditions affect the formation of discontinuity during friction stir lap welding of dissimilar Al-Cu joints. The materials comprised…

A two-step modelling procedure, consisting of a thermo-fluid model and a thermo-mechanical model, was employed to predict temperature, flow and residual stress fields around the workpiece block, steel backing plate and tool in friction stir welding …

A thermal-pseudo-mechanical model, based on the use of material temperature-dependent yield stress as the driver for heat input, was proposed for heat generation in friction stir welding, and simulation results were compared with experimental temper…

Butt joints were fabricated in sheet specimens of 2017A-T451 alloys (Al, 4.14%Cu) and cast plates of Al, 8.6%Si, 0.31%Mg by friction stir welding (FSW) and their microstructure and mechanical properties were investigated. Welding experiments were co…

Friction stir welding experiments were undertaken on 2195-T8 (Al, 3.99%Cu, 1.09%Li) alloy sheets (thickness 5 mm) and the weldability, microstructure and mechanical properties of the fabricated butt joints were investigated. Welding was performed us…

The application of suitable friction stir welding (FSW) tools and procedures to common structural geometries in industry, with emphasis of FSW of hard metals including steel, titanium and nickel based alloys in butt, T-joint, corner joint and circum…

A controller was developed and tested for the friction stir welding of copper canisters, used in the nuclear industry. The cascaded loop controller determines the power input requirement and tool temperature to achieve a stable, robust and repeatabl…

A friction stir welding tool with a variable length probe (suitable for variable thickness joints, repairs and circumferential welding) was developed and evaluated for the welding of aluminium alloy 2195. Tapered sheet, of both increasing and decrea…

Dissimilar lap joints between aluminium alloys and various steel grades were fabricated by friction stir welding (FSW), FSW tool wear was measured and a phenomenological law was developed with respect to pin length reduction over weld length to repr…

A review is presented of the progressive emergence of conceptual tools associated with friction stir welding (FSW) at the Marshall Space Flight Center, USA, from the discovery of the shear surface, wiping metal transfer and the invention of a kinema…

Weld zone simulation and ballistic testing were employed to determine the effect of friction stir welding on the ballistic performance in the HAZ, thermomechanically affected zone and nugget, under direct impact, of AA 7010-T7651 high-strength alumi…

A cathodic hydrogen charging method was employed to investigate hydrogen embrittlement in the parent metal and stir zones of friction stir welded SK4 high carbon steel (0.95%C, 0.42%Mn, 0.15%Cr) sheet specimens (thickness 2 mm). Welding was conducte…

Tapered probe and parallel probe tools were employed in friction stir welding of thick section AA 6082-T6 aluminium alloy specimens (thickness 38 mm) and the effect of tool geometry on weldment microstructure and crystallographic texture was investi…

With regard to the problem of parameter development for friction stir welding (FSW) of workpieces with 3D joints, a self-tuning algorithm is presented based on the tool-workpiece thermocouple (TWT) method for temperature measurement to facilitate th…