TWI Digital Library

Dissimilar lap joints were fabricated between 6022 aluminium alloy and SPCC low carbon steel using friction stir welding (FSW) and the effect of probe tip position on microstructure and mechanical properties was investigated. FSW was performed at a …

Based on lessons learned from the MegaStir research programme devoted to friction stir welding (FSW) of high temperature alloys and with the aim of producing high quality, defect free welded joints while maximising tool life, a report is presented i…

Neutron and synchrotron x-ray diffraction techniques were employed to determine the effect of global mechanical tensioning on residual stress in friction stir welded joints fabricated in AA 2199-T8 (Al, 2.63%Cu, 1.56%Li) and AA 7449-W51 (Al, 7.5-8.7…

Friction stir welding (FSW) experiments on aluminium alloys were conducted using transparent PVC material to visualise dynamic material flow by direct observation, and the characteristics of two types of vortex were investigated. A single block of P…

A methodology is presented to define conical tool geometry and process parameters for friction stir welding (FSW) of thin plates. A calculation algorithm integrating a basic thermal model, tool geometry and process kinematics is proposed, the proces…

A friction stir welding (FSW) procedure, incorporating the use of different tool pins in combination with concave or scroll type shoulders, was employed to join various aluminium alloys; material flow was investigated with the aid of computer micro-…

With regard to the development of the stationary shoulder friction stir welding (FSW) technique as a long term loading joining process offering enhanced weld seam mechanical properties, an investigation is presented into coordinated material flow be…

Modelling tools were developed to describe the relationships between process parameters, microstructural evolution and mechanical properties of the weld in friction stir welding (FSW). Experiments were conducted using aluminium alloy 6056. Initial t…

Computational fluid dynamics (CFD) methods were used to model the metal flow in the friction stir welding (FSW) process in order to optimise the pin profile to minimise the traversing force; welding experiments were carried out to validate the findi…

Friction stir welding (FSW) was investigated in aluminium alloys used in aircraft structures. Extruded shapes in alloys 2024 (Al, 4.96%Cu), 7475 (Al, 5.96%Zn, 2.57%Mg, 1.62%Cu) and 7050 (Al, 6.29%Zn, 2.36%Mg, 2.00%Cu) were welded; welds were evaluat…

The influence of friction stir welding on the microstructure and mechanical properties of aluminium alloy 6061 was investigated. Aluminium alloy 6061-T651 plate of 6.4 mm (0.25 in) thickness was friction stir welded and the joints characterised by o…

Ni3Al/Ni3V dual two-phase intermetallic alloys, incorporating Ta and Re additions, with enhanced high-temperature strength and hardness, were developed for friction stir welding tool applications and applied to fabricate butt welds in SUS 430 steel …

Modified Gleeble hot torsion testing was used to simulate four microstructure regions in HSLA-65 steel (0.07%C, 0.24%Si, 1.5%Mn, 0.14%Cr, 0.34%Ni, 0.25%Cu, 0.06%Mo) joints fabricated by friction stir welding (FSW) and the results were verified by op…

An approach to welded joint inspection incorporating in situ characterisation of weld quality was developed to facilitate the detection of discontinuities (e.g. voids and volume defects) during friction stir welding (FSW). FSW experiments were perfo…

A friction stir welding (FSW) process map for AA 7075-T6 aluminium alloy (Al, 5.1-6.1%Zn, 2.1-2.9%Mg, 1.2-2%Cu) was determined using combined NDT techniques such as visual inspection, dye penetrant testing, X-ray radiography and ultrasonic testing a…

In relation to weight and cost saving on spaceflight pressure vessels, two friction stir lap welding methods were demonstrated on large-scale thin-gauge hardware and evaluated with respect to tooling and tooling cost reduction, lap joint stiffness a…

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 …

The relationship between microstructure and properties, and the influence of microstructure on the fracture toughness of friction stir welded aluminium alloys with weld zone strength undermatching were investigated. Welds were made in 5005-H14, 2024…