TWI Digital Library

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…

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…

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 …

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…

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 …

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 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…

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…

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…

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…

In this study, the improvement of process stability of bobbin tool FSW for long welding length was studied. The base material used in this study was 18mm thickness 5083-O Al alloy. Floating bobbin type tools were used in this study. FSW produced def…

Bobbin-tool friction stir welding (BT-FSW) is a variant process of conventional friction stir welding with a particular tool configuration composed of an additional lower shoulder, enabling additional heat input and complete penetration of the pin. …

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…

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…

Fatigue crack initiation and propagation was studied in friction stir welded aluminium alloy 7010-T7651 and also in the parent alloy, using a combination of theoretical and experimental techniques. Finite element analysis was used to model the stres…

A method investigated by Sweden for storage of nuclear waste in copper canisters sealed using friction stir welding (where EB welding has been used before) is described. Topics include: Nimonic 105 and Densimet sintered tungsten alloy tool; welding …

The numerical simulation of the friction stir welding process using two different commercial finite element codes is described. FORGE3, which uses an updated Lagrangian approach, was used to simulate the plunge of the pin and the THERCAST package, w…

Evaluation of phased array ultrasonic inspection for the detection of typical friction stir weld defects is reported. Characteristics of friction stir welds with respect to inspectability are described. Phased array operation is outlined. A variety …

Friction stir welded joints in aluminium alloy 6061-T6 sheet were produced using a robot arm, to assess the ability of the arm to withstand the mechanical stresses associated with friction stir welding. The arm was fitted with an electrically powere…