TWI Digital Library

The effects of friction stir welding (FSW) parameters and tool geometry on the forces and torques generated during the FSW of four aluminium alloys were studied. The alloys were 6082-T6 (6.45 mm), 5083-H111 (6.55 mm), 2014-T6 (5.9 mm) and 7075-T7351…

Dissimilar joints between AA 6060-T5 aluminium alloy plates (thickness 6 mm) and Ti-6Al-4V titanium alloy sheets (thickness 2.5 mm) were fabricated by friction stir lap welding (FSLW) and the influence of interface microstructures on the value of ma…

WC, 12%Co cemented carbide layers were deposited onto M2 tool steel (0.8-0.88%C, 3.8-4.5%Cr, 4.7-5.2%Mo, 5.9-6.7%W, 1.7-2.1%V) substrates by HVOF spraying and the effect of subsequent friction stir processing (FSP) on bonding strength and cermet coa…

In order to understand the complex interactions between deformation, recrystallisation and precipitation induced during friction stir welding, two aluminium alloys were studied: a work hardened 5251-O alloy (Al, 2.2%Mg) and a precipitation hardened …

A coupled Eulerian-Lagrangian approach with Abaqus v.6.14 finite element software was employed to model the whole friction stir welding (FSW) process within one continuous model and results for temperature fields, surfaces, weld formation and proces…

A discussion is presented on the development of a FSW process for the welding of thin gauge aluminium alloy lap joints in the fuselage and wing sections of the Eclipse 500 twin-engine jet aircraft. The issues of pin tool geometry for use on lap join…

A new aluminium-bodied, mid-engined AUDI sports car is the first serial application for friction stir welded tailored blanks worldwide. 6th International Symposium, 10-13 Oct 2006, Session 9B: Modelling II, Paper 03

A moving gantry five axis CNC friction stir welding (FSW) machine was developed to facilitate the production of complex curved fuselage components (e.g. stringer and frame) based on third generation 2A97 Al-Li alloys. A ribbed curved component incor…

A comparative investigation was undertaken of MIG and friction stir welding of AW 6082-T6 alloys (Al, 0.63%Mg, 0.84%Si, 0.71%Mn) for marine applications such as structural panels in pontoons, and the welded joint microstructure and mechanical proper…

Friction stir spot welding experiments were conducted in a cross-tension configuration on automotive grade A 6002-T4 sheets (thickness 1 mm) and the effect of pin and shoulder geometry on welded joint static strength was investigated. The welding pa…

This study explores the microstructural evolution of AA6060 builds that were fabricated via the recently developed Friction Screw Extrusion Additive Manufacturing (FSEAM) approach, and the role of a subsequent post-manufacturing ageing heat treatmen…

In this study, RFSSW of similar 5052-0 and 6061-T6 aluminum alloys with various thickness from 1.0 mm to 3.0 mm were performed by using cemented carbide tools. Microstructural features and mechanical properties of the joints produced with optimized …

The optimal conditions for the friction stir welding of high-N-containing austenitic stainless steel were evaluated. The influence of heat input (welding speed (50-400 mm/min)) on the surface appearance, macrostructure, microstructure, hardness, yie…

The friction stir welding of lap joints of aluminium alloy 6061 sheet of 3 mm thickness was monitored using a variety of sensors, to establish systems for weld quality control. A triaxial dynamometer measured the forces on the workpiece in three per…

FSSW has been performed in two different automotive 1.5 mm-thick aluminium alloys– AA5754-H22 and AA6082-T6 in similar and dissimilar combination using different joining parameters (e.g. plunge rate, rotational speed and dwell time). Plunge depth ha…

A techno-economic assessment study was undertaken with respect to the feasibility of the friction stir welding (FSW) technique for microalloyed DH36 grade shipbuilding steel (0.11%C, 1.48%Mn, 0.02%Nb, 0.02%Al) plates (thickness 6 mm). Single sided f…

In relation to the generation of oscillating process forces during friction stir welding (FSW), hypotheses covering phenomena that can lead to dynamic effects were formulated and a finite element model of the process-machine-system (containing both …

A computational fluid dynamics package, FLUENT, was used to model the viscous material flow during friction stir welding using two- and three-dimensional tool shapes. Two approaches were used to describe the viscosity. The first approach interpolate…

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…