TWI Digital Library

The Welding of Airframes by Friction Stir (WAFS) project was implemented to increase the adoption of friction stir welding (FSW) for welding airframes in the aerospace industry. The partners in WAFS include all the main airframe manufacturers in Eur…

The use of friction stir welding in aircraft manufacture, particularly the Airbus, both as an alternative to riveting and for the production of tailored blanks, is discussed. Potential benefits include cost and weight reduction. The European aircraf…

Friction stir welding developments, equipment, and applications for the joining of aluminium alloys, particularly for automotive applications, are reviewed. Body in white automotive applications include aluminium alloy tailor welded blanks and the m…

Stress corrosion cracking in friction stir welded aluminium alloy joints was investigated using two alternative techniques. Aluminium alloy 7050-T7541 (Al, 5.7-6.7%Zn, 2.0-2.6%Cu, 1.9-2.6%Mg, 0.15%Fe, 0.12%Si) plate of 6.35 mm (0.25 in) thickness wa…

Based on the detailed analysis of the microstructure on top surface of friction stir welded (FSW) joint of 2024 aluminum alloy by optical microscope, XRD and transmission electron microscope. SEM was employed to obtain the in-situ corrosion developm…

An investigation was undertaken to evaluate the separation forces exerted by the tool on the fixture compared to the weld process loads generated during butt welding of self reacting bobbin friction stir welds. Two tempers of an aluminium alloy were…

An investigation was undertaken to explore the feasibility of welding baseline aerospace aluminium alloys along with additional constituents, such as coatings and a faying surface sealant, by the refill friction stir spot welding (RFSSW) technique a…

The material point method based on NairnMPM software was employed to formulate a 2D model of elastoplastic material flow around a friction stir welding (FSW) tool probe and to examine 2D elastoplastic deformation and the frictional interaction at th…

A thermal numerical 3D model to predict temperature and machine torque values for bobbin tool friction stir welding (FSW) is presented. The model includes a 3D representation of the work piece, clamping and bobbin tool. The heat transported by the t…

Incorporation of friction stir welding (FSW) in a parallel kinematics machine (PKM) 5-axis machine was undertaken with the intelligent computer aided manufacturing (ICAM) approach to optimise process parameters and tool paths by using available CNC …

Spot welds were fabricated in DC01 mild steel and HC 420-LA high strength steel sheets (thickness 1 mm) by friction stir spot welding (FSSW) using various pinless tools and process parameters, and thermographic analysis together with microstructural…

Friction stir welding (FSW) experiments were undertaken on single crystal and polycrystalline pure iron sheets (thickness 1.5 mm) as well as a polycrystalline carbon steel, and the microstructure, material flow characteristics and plastic deformatio…

Dissimilar butt joints were fabricated between two aluminium alloys, 2017A-T451 (Al, 4.14%Cu, 0.72%Mg) and AlSi9Mg (Al, 8.6%Si, 0.31%Mg), by friction stir welding (FSW) using a dual-speed tool and their microstructure and mechanical properties were …

The linear friction welding of carbon steel using low frequency and low amplitude so as to weld below the A1 transformation temperature and so avoid martensitic transformation was investigated. The end faces of JIS-S45C carbon steel (0.48%C, 0.77%Mn…

An investigation was carried out in order to examine the feasibility of producing friction stir welded FSW T-joints using the corner fillet geometry. A specific tool comprising a rotating pin (made of MP159) with a 45 degree inclination to the two p…

An experimental investigation was undertaken to examine the effect of a TIG welding torch assisted heating source on the microstructure, mechanical properties and fracture mechanism of dissimilar Cu/austenitic stainless steel butt joints fabricated …

Tensile tests, computed tomography and documentation of process forces were employed to investigate the weldability of 1.4310 austenitic stainless steel reinforced extruded AW-6060 alloy (Al, 0.35-0.6%Mg, 0.6%Si) by friction stir welding, and the re…

Friction stir welding experiments were undertaken on rolled plates (thickness 25.4 mm) of AA 6061-T6 aluminium alloys to investigate the role of backing plate material on thermal gradient changes in the through-thickness direction. Welding was perfo…

Following a brief overview of the state of the art and applications for FSW of aluminium and Al alloys, experience and activities with this process at TWI Ltd (UK) are introduced. Principles, advantages and applications are presented of some process…

Friction stir welding experiments were undertaken on carbon manganese steel plates (thickness 6 mm) in order to map the internal temperature distribution, assess the effects of minimal plate preparation and investigate the microstructures and mechan…