TWI Digital Library

An investigation is presented into the processing window for friction stir welding (FSW) of Formall 545 (equivalent to AA-5083) to age-hardened AA-6082 aluminium alloys with regard to tool rotation and traverse speeds, and into an evaluation of a nu…

5083-O aluminium alloy sheets (thickness 3 mm) were butt welded using a gate-type friction stir welding (FSW) machine to investigate tolerance to deviations in butt-line/tool-travel line, gap spacing and tool roll angle, and the welded joints were e…

In relation to the application of tailor welded blanks of aluminium alloys to the vehicle weight reduction process, an investigation is presented into the precipitation sequence in friction stir welded 6016 alloy sheets (thickness 2 mm) during a pai…

An experimental study was conducted to measure the torque of friction stir welded cast aluminium A356 (Al, 7%Si, 0.3%Mg) over a range of travel and rotational speeds. Plates of 6.35 mm thickness were FSW using travel speeds and rotational speeds ran…

The weldability of zirconium-titanium alloy joints fabricated by means of friction stir welding (FSW) was investigated. Sheets (thickness 3 mm) of Zr-Ti alloy (Zr, 41%Ti, 4%Al, 3%V) underwent FSW with a tungsten-rhenium alloy (W, 25%Re) tool with an…

With regard to the development of Al-Mg-Sc alloys for aerospace applications, an investigation is presented into friction stir welding (FSW) of thick plates (thickness 35 mm) and thick-walled pipes made from 1570C alloy (Al, 5.7%Mg, 0.29%Mn, 0.2%Sc,…

Bead-on-plate welds were fabricated in S31254 superaustenitic stainless steel (19.82%Cr, 17.78%Ni, 6.13%Mo) plates (thickness 6 mm) using friction stir welding (FSW) and their microstructure and texture evolution were studied by high resolution elec…

A fully coupled thermomechanical three dimensional finite element (FE) model was developed to analyse the thermomechanical conditions, including material flow and heat generation, at the tool/matrix interface in friction stir welding. The model was …

An abrasion circle friction stir spot welding (ABC-FSSW) technique was employed to fabricate dissimilar metal joints between aluminium and steel automotive sheets, and the microstructure, mechanical properties and weld formation mechanisms of the jo…

With regard to inconsistencies in the literature concerning the correlation between friction stir welding (FSW) process inputs and post weld process or material response, an investigation is presented into the primary variables (temperature, cooling…

A friction stir processing (FSP) technique was employed to fabricate D2 steel hunting knife blades with long-life cutting edge retention, and blade integrity tests were undertaken. The FSP tool design was a convex scroll shoulder step spiral and the…

Friction Stir Welding (FSW) is a relatively new technique which utilizes frictional heating combined with a forging pressure to produce virtually defect-free high strength bonds. Although considerable experimental work has been reported in the liter…

Friction stir lap diffusion welding was employed to fabricate dissimilar AA 6060 aluminium alloy/mild steel joints and mechanical testing and metallurgical examination of the weldments were undertaken to investigate the effect of microstructure form…

Similar overlap and dissimilar butt joints were fabricated by friction stir spot joining of AA 6061-T6 (Al, 1-1.1%Mg, 0.66-0.67%Si) and AA 5052-H34 (Al, 2.58%Mg) sheets of thickness 1 and 2 mm, respectively, and microstructural analysis was used to …

An finite element method (FEM) model, considering variables such as tensioning level, heat input and sheet geometry but ignoring mechanical tool effects, was developed to investigate the efficacy of the mechanical tensioning technique for controllin…

A 3D computational fluid dynamics model was developed to conduct numerical simulations of heat generation, material flow and temperature profiles during reverse dual-rotation friction stir welding, a process variant in which the tool pin and the ass…

SiC particle reinforced 2124Al metal matrix composite (MMC) plates (thickness 8 mm) were joined by friction stir welding (FSW) and the relationship between process parameters, weld defect formation and joint mechanical properties was investigated. T…

The microstructures and strengthening mechanisms during friction stir processing (FSP) of AZ91 (Mg, 9%Al, 1%Zn) die-cast and Mg-Y-Zn (Mg, 5.9%Y, 2.6%Zn and Mg, 5.5%Y, 4.3%Zn) cast alloys were investigated and the effect of second phase particle disp…

Numerical simulation of the friction stir welding (FSW) process was undertaken by means of an arbitrary-Lagrangian-Eulerian (ALE) formulation and a fully coupled thermomechanical analysis was performed to account for the heat flux generated by plast…

3-point fatigue bending tests and finite element method simulations were employed to study the fatigue performance of combined lap-butt joints fabricated by friction stir welding in 6005A-T6 alloy (Al, 0.61%Si, 0.54%Mg) extruded profiles for railway…