TWI Digital Library

Butt welding experiments were undertaken to investigate the feasibility of joining a metal matrix composite (MMC), comprising an Al-10%Si matrix and 20 vol.% SiC particles, to an AA-6063-T5 alloy by friction stir welding (FSW). Optimum process param…

An algorithm and procedure for controlling process zone temperature during friction stir processing are presented. The approach is based on the correlation between weld zone temperature with spindle power. A simplified thermal balance model of the w…

Friction stir processing (FSP) experiments were undertaken to modify the microstructure of Ti-6%Al-4%V parent metal specimens, in both alpha/beta and beta processed conditions, and TIG weld overlays deposited onto Ti, 6%Al, 4%V alloy using matching …

The design of a polycrystalline cubic boron nitride friction stir welding tool, tool holder and machine for use with high melting temperature materials is described. A polycrystalline cubic boron nitride truncated cone tool tip, capable of working a…

Friction stir welds were made in 4 mm thick sheets of aluminium alloys 2024-T3 and 6013-T6. The stress intensity factor due to residual stresses was determined using the cut compliance method. The residual stress distribution was calculated using th…

Similar and dissimilar joints between 2014-T6 (Al, 4.67%Cu) and 6061-T6 (Al, 0.9%Mg, 0.63%Si) aluminium alloys were fabricated by friction stir welding (FSW) with various sets of process parameters, and the microstructure and mechanical properties o…

The tolerance of operational accuracy and optimum tool control in 3D friction stir welding (FSW) was investigated in relation to joint mechanical properties. A five-axis controlled FSW machine was developed for 3D welding. The material studied was a…

With regard to the dependence of welded joint properties on tool probe shape during friction stir welding (FSW) of dissimilar butt joints between aluminium and steel, an investigation was undertaken into the interface formation mechanism by conducti…

The friction stir welding of dissimilar aluminium alloys for the production of aircraft structural components was investigated. Welds were made between alloys 7040 and 7449 pre-aged to obtain a defined temper after post-weld ageing. Alloy 7040 was a…

An investigation is presented into the fatigue properties of welded joints in various structural aluminium alloys prepared by friction stir welding (FSW) and the results are compared with those measured on MIG welded joints. The experimental specime…

Friction stir spot welded joints in aluminium alloy 6061-T4 were studied. Sheet of 1, 1.5, 2, and 3 mm thickness was friction stir welded to sheet of 3 mm thickness, using welds of 8-18 mm in length (equivalent in area to circular resistance spot we…

Dissimilar lap joints between ASTM A36 low carbon steel and Inconel 625 (Ni, 21.4%Cr, 9.65%Mo, 3.2%Nb, 2.6%Fe) were fabricated by friction stir welding (FSW) and the effects of process parameters on microstructure and hardness were investigated. FSW…

An investigation is presented into the effect of frictional heating on joint behaviour during friction stir welding (FSW) between aluminium alloy 6063 and mild steel S45C, the cross-section microstructure of the weld interface, and the welding mecha…

Very high speed (10m/min [394 ipm]) friction stir welding (FSW) was demonstrated in both 2 mm thick AA6061-T6 and AA5051-H32. For AA6061-T6, weld parameters of 2,025 kg (4,500 lbs.) at 10,000 rpm and for AA5052-H32 weld parameters of 1,665 kg (3,700…

A 3D fully coupled computational fluid dynamics model was established to investigate the heat generation and material flow during friction stir welding, and the measured tool torque and axial force were used to characterise the contact conditions (f…

Friction stir welding (FSW) was carried out on AZ31 magnesium alloy (Mg, 3%Al, 1%Zn) plates of thickness 6 mm in order to examine the relationship between weld microtexture and tensile properties. Orientation imaging microscopy was used to examine m…

A nonlinear dynamic model to study the axial force and torque in the tool of a friction stir welding (FSW) process was developed by training an artificial neural network (ANN) multi-perceptron layer structure with a nonlinear autoregressive exogenou…

A simplified friction stir welding (FSW) tool equipped with an adjustable probe was developed, FSW trial results with prototype tools were obtained and were analysed in terms of weldability. The simplified tools were realised by devising shoulders f…

A flat heat pipe with Al2O3 nanofluid or deionised water as the working medium was designed, the relationship between pipe parameters and heat transfer characteristics was analysed, and the application of the heat pipe to friction stir welding was e…

A qualitative and discrete quantitative approach was adopted to develop a generalised electronic NDE (e-NDE) algorithm for identifying erratic friction stir welding (FSW) indications contained in the tool force feedback signals as low and high frequ…