TWI Digital Library

A feasibility study is presented for the joining of mild steel plates (0.2%C, 0.11%Si, 0.63%Mn) of 12 mm in thickness by friction stir welding (FSW). Process optimisation using a combination of operating parameters and tool geometries is discussed, …

A thermomechanical finite element model of the friction stir welding process, which considered temperature distributions in the workpiece and tool loadings, was developed and validated by comparing the model simulations with experimental data for th…

A discussion is presented on the industrial use of the friction stir welding (FSW) process looking at cost issues and technological developments. The cost implications of introducing FSW into production areas and the calculation of returns on invest…

The forces exerted on the pin of a friction stir welding tool with a variable length pin (retractable pin-tool) were measured whilst welding aluminium alloy 2195 plate of 8.4 mm thickness, to develop a closed loop control system. Forces were measure…

The feasibility of friction stir welding steels was investigated using mild (low-carbon) steel plate (AISI-1010) of 6.4 mm (0.25 in) thickness. Temperature distributions were predicted using a simple thermal model. Tool wear was assessed by determin…

Microstructural evolution in friction stir welded commercially pure aluminium 1100-O plate was investigated. Plate of thickness 6.35 mm (0.25 in) was welded using rotational speeds of 700 and 1200 rpm, and welding speeds of 180 and 580 mm/min. The m…

Dissimilar lap joints between 2024-T3 aluminium alloy (Al, 4.6%Cu, 1.3%Mg, 0.56%Mn) and Ti-6Al-4V titanium alloy (Ti, 6.21%Al, 3.99%V) were fabricated by friction stir welding (FSW) and the influence of process parameters on hook shape and surface r…

A round robin investigation was made to determine if defects found using the non-destructive evaluation (NDE) techniques of ultrasonic phased array and x-ray inspection, can be identified by a real-time, feedback-based friction stir weld analysis to…

Dissimilar joints between the aluminium alloys 2017A-T451 (Al, 4.14%Cu, 0.72%Mg, 0.68%Si, 0.6%Mn) and AlSi9Mg (Al, 8.6%Si, 0.31%Mg, 0.34%Mn) were fabricated by friction stir welding and computerised microtomography was employed to visualise defects.…

An investigation is presented into the occurrence of a grey line in x-ray diffraction of friction stir welded joints of AA 2024-T62 aluminium alloys, and its influence on mechanical and fatigue properties. Welding in 2 mm sheet was performed using a…

Precipitation hardened copper alloy sheets (thickness 2 mm) containing Cu, 0.9-1.2%Cr, 0.06-0.09%Zr were joined by friction stir welding (FSW), process parameters were optimised to realise defect-free joints, and the microstructure and mechanical pr…

To meet the needs of lightweight automobile design to join thin steel structures to thicker aluminium sheets, two joint geometries for high-strength friction stir welding (FSW) of dissimilar and unequal thickness sheets were developed: one involving…

A review is presented of various models developed to understand the effects of thermal cycles and metal flow behaviour on the microstructure and properties of welded joints fabricated by friction stir welding of steel, and a comprehensive numerical …

An integrated multi-physics model was employed to predict the temperature distribution, the post-weld grain size distribution and the local subgrain size distribution around the pin during friction stir welding (FSW) of 6061 aluminium alloys. The mu…

Metallographic observations, hardness distribution measurements and fatigue tests were undertaken to investigate the discontinuity state related to the crack nucleation site in butt joints fabricated in 2024-T3 aluminium alloys (Al, 3.8-4.9%Cu, 1.2-…

In relation to the application of friction stir welding (FSW) to the production of metallic aircraft fuselages, a report is presented into the evolution of the MUVAX (multi use vacuum assisted exoskeleton) concept within the framework of the LuFo V-…

A tool made from a Co-based alloy strengthened by precipitation of an intermetallic Co3(Al,W) gamma phase with an L12 structure was developed for friction stir welding of high-softening-temperature materials, such as a 0.45%C steel, and the tool wea…

Annealed AISI 420 martensitic stainless steel (0.46%C, 0.3%Mn, 13.8%Cr) sheets (thickness 3 mm) were subjected to dry or wet friction stir processing (FSP) and the correlation between microstructure, hardness and process parameters was investigated.…

A detailed experimental and theoretical investigation was made of the use of friction stir welding (FSP) to modify the microstructure of magnesium AM50 die castings. Rectangular die cast plates of 3 mm thickness of AM50 (Mg, 4.9%Al, 0.39%Mn) were su…

The velocity field in the shear layer surrounding the tool/matrix interface in friction stir welding (FSW) was used to characterise material flow and was investigated by x-ray/computational tomography (CT) marker material experiments as well as anal…