TWI Digital Library

A friction stir welding (FSW) process based on the use of a self-reacting pin tool (SRPT) was developed for the joining of solid and hollow extrusions for aluminium railway car body structures; the mechanical properties of welded joints were investi…

Butt joints were fabricated in AA 2219-T87 aluminium alloy panels (thickness 6.35 mm) by friction stir welding (FSW), and force data collected during welding were analysed using an unsupervised matched filter technique to classify weldment segments …

Friction stir butt welds of Al alloy (2024, 6013 and 6056) sheets (4 mm thickness) were examined by conventional ultrasonic inspection with a single focused transducer (25 MHz frequency), facilitating the detection of void-like flaws as well as the …

A description is presented of the friction stir welding (FSW) machine developed for fabrication of the external fuel tanks for the Space Shuttle. The cylindrical part of the tanks was composed of curved panels welded into barrels with welds of const…

A review is presented of process development work undertaken with regard to a machine concept assessment and the realisation of a fully 3D-capable 5-axis parallel kinematic friction stir welding machine, a so-called pentapod, suitable for large and …

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…

Friction stir spot welding experiments were conducted on dissimilar metal joints between AA5052 aluminium alloy and three kinds of zinc coated steel, and weldability analysis, microstructure observations and mechanical tests were undertaken. The coa…

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 …

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…

Friction stir welding (FSW) experiments were conducted on magnesium alloys, wrought AZ31 (Mg, 3%Al, 1%Zn) and cast AZ91 (Mg, 9%Al, 0.6%Zn), to investigate the effect of process conditions on microstructure and hardness. Welding was performed at rota…

An experimental investigation is presented into the fatigue properties of welded joints made by friction stir welding (FSW) of 2024-T4 (Al, 4.4%Cu, 0.6%Mn, 1.5%Mg) and 2014-T6 (Al, 4.5%Cu, 0.8%Mn, 0.5%Mg) aircraft alloys and their dependence on proc…

Extruded AZ31 (Mg, 3%Al, 1%Zn) alloy plates (thickness 6 mm) were joined by one-run or two-run friction stir welding (FSW) and the microstructure, mechanical properties and residual stress characteristics of the welded joints were investigated. FSW …

Friction stir welding experiments were undertaken on Ti-6%Al-4%V sheets (thickness 2 mm) in order to investigate the influence of process conditions on stir zone microstructure and local texture. Welding was performed at rotational speeds of 225-300…

With regard to the occurrence of residual oxide defects associated with friction stir welding (FSW) of aluminium alloys, an investigation is presented into a possible alternative mechanism for oxide formation within the weld nugget involving enhance…

Quantification approaches applied to phase space data generated from friction stir welding aluminium alloys under varying process conditions are reported. A multi-step, micro-wormhole, non-destructive evaluation phase-spaced, (PS) algorithm that com…

Numerical simulations and experimental tests were undertaken to visualise material flow and to study the effect of the flow field on the mixing mechanism and particle break-up in friction stir welding of metal matrix composites. A 3D thermo-fluid mo…

Nondestructive testing of friction stir welds is discussed. The ultrasonic testing of friction stir welded joints, advantages of phased array testing and test applications are presented briefly. The eddy current array testing technique is illustrate…

Fatigue tests were performed using lap-shear specimens of friction stir spot welded Al, 0.8%Mg, 1%Si alloys. Sheet specimens (thickness 2 mm) were subjected to PWHT of solution treatment and/or ageing. Weld zone microstructure was observed by SEM. F…

The joining of hot rolled aerospace quality AZ31B-H24 magnesium alloy (Mg, 2.5-3.5%Al, 0.7-1.3%Zn, 0.2-1.0%Mn) sheets (thickness 4.95 mm) was investigated using an MTS ISTIR friction stir welding (FSW) machine, the quality of the butt joints produce…

A brief review is presented of the state of development of polycrystalline cubic boron nitride (PCBN) tool materials for friction stir welding (FSW) of high-temperature materials (high alloy steels and Ni based alloys) with respect to weld penetrati…