TWI Digital Library

As part of a project to develop a physical-mathematical model and software for thermal simulation of the friction stir welding (FSW) process, an initial version "FricSim2.2" was created and verified, using the software tool "SpotFSW" to convert the …

The incorporation of strips of copper foil in friction stir welded aluminium alloy plate was evaluated for flow visualisation without disturbing the welding process. The strips, of 0.1 mm thickness, were placed in various longitudinal and transverse…

The design and construction of a prototype fixture and a corner fixture for making 90 degree corner joints in aluminium alloys by friction stir welding (FSW) are described. The requirements for a FSW weld fixture are outlined. The fixtures were test…

The microstructure of a friction stir weld (of unknown welding parameters) in titanium alloy (Ti, 6%Al, 4%V) is described. The microstructure was studied using optical microscopy, SEM and TEM. The features of the parent material, HAZ and the thermom…

Guidance notes devised for Lloyd's Register of Shipping surveyors for use in the quality assurance of friction stir welded aluminium alloys are presented.The notes cover: welding equipment, materials welded, and welding requirements (weld qualificat…

The friction stir welding of copper for the production of spent nuclear fuel storage disposal canisters was investigated. Initial trials were conducted on UNS-C10100 plate of 10 mm thickness. The high temperatures required the use of a sintered tung…

A process model for friction stir welding (FSW) of Al-Zn-Mg alloys, used to predict HAZ microstructure and hardness, is presented. Numerical solutions (using a finite difference approach) are developed for heat generation and heat flow. Microstructu…

Friction stir welding is widely applied in several industries such as manufacturing rolling stock, automotive parts and ship building. Especially, EV will be expected to popularize in these two or three decades in view of reducing CO2. The parts of …

Fatigue crack growth in friction stir welded (FSW) aluminium alloys 2024-T3 and 6013-T6 were predicted using two commercial software programs, ESACRACK and AFGROW in order to facilitate lifetime predictions of FSW aircraft structures. The following …

The feasibility of using friction stir welding (FSW) in the construction of an aircraft central wing box from butt-welded extrusions was evaluated. An FSW procedure for welding 7055 T77511 and 7349 T6511 10 mm thickness extrusions was developed by T…

The application of friction stir welding (FSW) to the fabrication of copper backing plates of thickness 6 mm was investigated. The welding conditions, FSW machine development, and mechanical and metallurgical properties of friction stir welded joint…

The design, construction and use of a purpose-built friction stir welding machine for the welding of 15.9 mm (0.625 in) thickness, 1.88 m (74 in) long aluminium alloy 6061-T6 plate and extruded sections to form the side panels of a laser system is d…

The repair of friction stir weld defects in aluminium alloy 6061-T6 3 mm thickness sheet (Al, 0.683%Mg, 0.564%Si) by friction stir welding was investigated using artificial defects. The defects were created using an unsuitable pin profile, whilst re…

A softening model was constructed for friction stir welding (FSW) of 2xxx series aluminium alloys and was combined with previously derived thermal cycle modelling work. A thermal model of energy input and heat conduction was used to calculate therma…

Control equipment for the friction stir welding process was developed and evaluated for the production of a 8.4 m (27.5 ft) diameter, 0.32 in (8.13 mm) wall thickness 2195-T8 aluminium alloy space vehicle external fuel tank. The use of a computer-ba…

Finite element analysis was used to model the friction stir welding process in 6061-T6 aluminium alloy plate, to predict temperature, residual stress and distortion. Temperature distributions in the workpiece were determined as a function of time, c…

Liquid metal dealloying is a promising method relying on the selective dissolution of a component from a precursor alloy into a liquid metal, resulting in production of bicontinuous porous surface on the precursor alloy. To expand use of the porous …

The non-destructive testing (NDT) aspects of the Qualistir project for the on-line quality control of friction stir welding in aluminium are described. Definitions are given for the following defects: voids, wormholes, lack of penetration, faying su…

The development of three-dimensional column-type friction stir welding (FSW) equipment for robotic FSW of joints with complex shapes is described. The process requires a large force and precision control for tool penetration. The specification of th…

The influence of pores and residual stresses on fatigue crack propagation was studied for friction stir welded joints in aluminium alloys 2024-T3 and 6013-T6 of thickness 4 mm. Good welds and pore-containing welds were produced using tools with and …