TWI Digital Library

An abrasion circle friction stir spot welding (ABC-FSSW) technique was employed to fabricate dissimilar metal joints between aluminium and steel automotive sheets, and the microstructure, mechanical properties and weld formation mechanisms of the jo…

This study addresses the challenges of predicting joint efficiency for friction stir welding (FSW). It adopts a data driven approach, leveraging data analytics to develop accurate predictive models. A database of 1780 records from diverse aluminium …

A description is presented of the self reacting friction stir welding (SR-FSW) process and the specially designed welding head; results are reported from tests determining the mechanical properties of SR-FSW welds in AA-2219 and AA-2195 aluminium al…

Similar overlap and dissimilar butt joints were fabricated by friction stir spot joining of AA 6061-T6 (Al, 1-1.1%Mg, 0.66-0.67%Si) and AA 5052-H34 (Al, 2.58%Mg) sheets of thickness 1 and 2 mm, respectively, and microstructural analysis was used to …

A friction stir processing (FSP) technique was employed to fabricate D2 steel hunting knife blades with long-life cutting edge retention, and blade integrity tests were undertaken. The FSP tool design was a convex scroll shoulder step spiral and the…

Alternative friction stir welding tool shoulder materials to improve welding speed and quality were evaluated. The materials, which were compared with tool steel using a tool designed for exchangeable shoulder inserts, were: nitrided tool steel, Inc…

A real-time wireless temperature measurement system was developed to facilitate improved temperature measurement at the tool-workpiece interface and a closed-loop control system for friction stir welding (FSW) that maintains weld quality under vario…

Experimental measurements and thermal modelling were used to determine the transient heat loss into friction stir welding tools and so calculate the welding efficiency. Energy inputs were determined from force and torque measurements made whilst per…

Multi-material structure is effective way to achieve lightening of vehicles for reduction of CO2 emission. Thus, carbon fiber reinforced thermo-plastic (CFRTP) and aluminum alloy (Al) are useful materials for lightening of vehicles. For fabrication …

A non weldable to weldable (N2W) methodology is presented in which friction stir welding (FSW) is used to join a non weldable (but highly wear resistant) material to a weldable material (e.g. a steel insert positioned within the wear resistant mater…

Experimental methods were developed to track material flow and mixing during the friction stir welding (FSW) process. Experiments were conducted with butt joints of 6.35 mm (0.25 in) thickness 7050-T7451 aluminium alloy plates. The FSW tool was H13 …

Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process dev…

Friction stir welding (FSW) has been used to weld aluminum alloys such as 7075 to 7075, which is considered not weldable by most other methods. In this application FSW was used to join two dissimilar aluminum alloys 7075 and 6N pure copper in a lap …

An extensive study of friction stir welding (FSW) of HSLA-65 steel plate (thickness 6 mm) was undertaken, incorporating defect-free friction stir butt welding at a travel speed of 3.4 mm/s, the achievement of low/no distortion FSW by employing appro…

Variations in microstructure in friction stir welds in AA 7449 (Al, 2.2%Mg, 8.2%Zn, 1.7%Cu, 0.12%Si, 0.15%Fe, 0.2%Mn, 0.05%Cr, 0.25 T plus Zr) in the initially overaged (T7) condition were studied. Isothermal heat treatments were conducted at 350 an…

This paper describes the joining criterion for lap joining of dissimilar metal materials of aluminum and stainless steel by friction stir. A criterion for evaluating the joined state or non-joined state is proposed, which is led by the concept based…

With regard to the production of wear resistant friction stir welding (FSW) tools by laser implantation of ceramic particles, an investigation was undertaken to examine the effect of laser implantation on tool surface hardness, abrasive wear and lif…

Friction stir welding experiments were undertaken on thin sheet specimens (thickness 0.8 mm) of 5754-H111 alloys (Al, 2.7%Mg) in a butt joint configuration, and the influence of process conditions on microstructural, mechanical and corrosion propert…

With regard to the production of aluminium alloy T joints for stiffened panel construction by friction stir welding (FSW), an investigation is presented into the fabrication of FSW T joints with AA 6082-T6 alloys and the influence of welding paramet…

Friction stir welding was employed to fabricate dissimilar joints between 5A06-H112 aluminium alloy (Al, 5.8-6.8%Mg, 0.5-0.8%Mn) and 304L stainless steel (0.03%C, 18-20%Cr, 8-11%Ni) and material flow behaviour was investigated by microstructure obse…