TWI Digital Library

The material flow in dissimilar material friction stir welding (FSW) between AA 6063 alloy (Al, 0.5%Mg, 0.43%Si) and S45C carbon steel (0.43%C, 0.25%Si, 0.77%Mn) was investigated by determining the 3D forces acting on the welded joint and the intern…

The ScanStir framework, comprising an experimental friction stir welding (FSW) set-up, numerical models based on open source finite element method software packages, and a high performance computer, was used to simulate the residual stress profile i…

Samples of AA 2219 aluminium alloy (Al, 5.8-6.8%Cu, 0.2-0.4%Mn) produced by electron beam freeform fabrication (EBF3), a wire fed process for additive manufacturing, were joined by friction stir welding (FSW) and the microstructure and mechanical pr…

Using a pin tool made from relatively low cost metallic materials, including heat resistant alloys (e.g. Ni-Cr) with or without surface treatment, suitable conditions were investigated for friction stir welding (FSW) of commercially pure (CP) titani…

The influence of welding tool design on the microstructure of the interface and friction stir spot welded joint between aluminium alloy and low carbon steel was investigated. Two types of welding tool were evaluated: a tool comprising a probe and sh…

A friction stir channelling process to promote a distinct material flow was developed, in which a controlled amount of viscoplasticised material from the metal workpiece flows out from the processed zone producing an internal channel without any gap…

Similar and dissimilar T-joints were made by friction stir welding (FSW) of 3 mm thickness 2024-T3 cover sheet combined with 2.5 mm thick stiffeners consisting of either 2024-T3 or 2098-T8 (stringer) material. During welding the pin penetrated the s…

Microstructure observations and bending tests were employed to investigate the basal plane texture and room temperature formability of AZ31 magnesium alloy rolled and extruded sheets (thickness 3 mm) treated by friction stir processing (FSP). Overla…

An experimental investigation was made of the effect of welding tool shape on welding defects and material flow during friction stir welding (FSW) of dissimilar materials. Friction stir welding tools used had tool shoulders of tool steel and the pro…

Fatigue testing was performed on welds joining AA2024 (AI4.5Cu1.4 Mg0.5Mn) alloy to TI6Al4V alloy by having AA100 strip as an interlayer utilizing friction stir lap welding (FSLW). During FSLW, the pin bottom was aimed not to touching the Ti6Al4V pl…

The stationary shoulder friction stir welding (SSFSW) process was employed to fabricate defect-free joints in a variety of aluminium alloys and experiments were undertaken to investigate the microstructure and mechanical properties of the joints. Th…

Numerical modelling and experimental measurements were undertaken to investigate the heat flux and residual stresses during a rotary friction welding process to fabricate joints between an ASTM A36 steel pipe (0.11%C, 0.2%Si, 0.92%Mn, 0.02%Cr, 0.02%…

The main factors to be considered in the automation and robotisation of friction stir welding (FSW) and the production of one-, two- and three-dimensional welds were identified. A FSW robotic cell was developed and force control algorithms were defi…

A fully Lagrangian smoothed particle hydrodynamics method was employed to simulate the bobbin tool friction stir welding process for aluminium alloys in order to evaluate tool torque and forces as well as material flow for different advancing speeds…

The corrosion behaviors of friction stir welded (FSW) joint of 7075 aluminum alloy with and without shot peening treatment (SPT) were investigated by method of acid salt spray. The macroscopical and microscopical corrosion features were observed by …

A device was designed and manufactured to facilitate accurate monitoring of forces, torque and tool temperature during friction stir welding (FSW) and for use as a weld quality indicator in relation to issues such as tool wear, lack of tool penetrat…

Following a summary of the current applications for friction stir welding at Boeing, the Brotje Automation FSW system is introduced. Presentation slides give notes on complex contour FSW in a large work envelope, the characteristics of a robust prod…

The large load friction stir spot welding (LL-FSSW) technique was applied to a low carbon steel sheet in order to achieve lap joints at a low temperature, and the microstructure and hardness of the joints were investigated. The composition of the gr…

A simultaneous double sided corner Ad-Stir fillet stationary shoulder friction stir welding (SSFSW) process was developed for LNG (liquefied natural gas) storage tank construction. The microstructure and mechanical properties of welded joints were i…

An experimental investigation was conducted into the effects of friction stir processing (FSP) and post-FSP ageing on the microstructure and mechanical properties of Alloy 718 castings. Bead-on-plate welds were fabricated on cast Alloy 718 sheets (t…