TWI Digital Library

In relation to the industrialisation of the friction stir welding process to facilitate qualification of welding machines for different applications, a methodology is presented based on the interactions between tool, workpiece and material. Issues d…

A report is presented into the "RoboFSW" project, intended to qualify a high payload articulated arm robot for friction stir welding (FSW); hardware modification and control system integration are described and 3D FSW capability is reported for circ…

A numerical and experimental study was undertaken to investigate the mechanism of swing friction stir spot welding (FSSW) and the effects of swing length and weld direction on the joint strength. Coupons were taken from a commercial A6022-T4 alumini…

Two abutting plates (thickness 6 mm) of Al 6061-T6 and cold rolled AISI 1018 mild steel were friction stir welded along the butt joint with the steel and aluminium, respectively, on advancing and retreating sides, and the relationship between proces…

Friction stir welding (FSW) using a milling machine was employed to join AA-6063-T6 alloy (Al, 0.51%Mg, 0.42%Si) pipes (diameter 110 mm, thickness 5 mm) with the aim of eliminating ploughing problems, and weld zone microstructures were studied as a …

Dissimilar joints between 6061-T4 aluminium alloy and S45C steel sheets (thickness 1.6 mm and 1 mm, respectively) were fabricated by the friction stir clinching technique using two types of tools and their mechanical properties and failure modes wer…

Friction stir linear welding and friction stir spot welding techniques were employed to fabricate robust and reliable welded joints for automotive front end substructure applications between AA6022-T4 aluminium alloy and AM60B magnesium alloy sheets…

The surface quality, microstructure and crystallographic texture were investigated as a function of traverse speed for friction stir welds of Ti-6Al-4V, produced using static shoulder tools consisting of a tungsten-rhenium probe and a silicon nitrid…

An investigation is presented into bead-on-plate friction stir welding of type 304 austenitic stainless steel (18.1%Cr, 8.56%Ni) and the relationship between corrosion properties and weld microstructure. Microstructural observations were performed b…

A feasibility study is presented for the joining of mild steel plates (0.2%C, 0.11%Si, 0.63%Mn) of 12 mm in thickness by friction stir welding (FSW). Process optimisation using a combination of operating parameters and tool geometries is discussed, …

A thermomechanical finite element model of the friction stir welding process, which considered temperature distributions in the workpiece and tool loadings, was developed and validated by comparing the model simulations with experimental data for th…

A discussion is presented on the industrial use of the friction stir welding (FSW) process looking at cost issues and technological developments. The cost implications of introducing FSW into production areas and the calculation of returns on invest…

The forces exerted on the pin of a friction stir welding tool with a variable length pin (retractable pin-tool) were measured whilst welding aluminium alloy 2195 plate of 8.4 mm thickness, to develop a closed loop control system. Forces were measure…

The feasibility of friction stir welding steels was investigated using mild (low-carbon) steel plate (AISI-1010) of 6.4 mm (0.25 in) thickness. Temperature distributions were predicted using a simple thermal model. Tool wear was assessed by determin…

Microstructural evolution in friction stir welded commercially pure aluminium 1100-O plate was investigated. Plate of thickness 6.35 mm (0.25 in) was welded using rotational speeds of 700 and 1200 rpm, and welding speeds of 180 and 580 mm/min. The m…

An investigation is presented into the fatigue characteristics of friction stir welded (FSW) lap joints made from artificially aged Al alloy 6082 (Al, 0.6-1.2%Mg, 0.7-1.3%Si) using a tool based on the "Triflute" concept with either convex or concave…

A 16-run screening design of experiments (DOE) was conducted to analyse the effects of nine factors during friction stir welding on process forces, temperatures and shoulder depth. The factors were spindle speed, feed rate, plunge depth, pin length,…

Friction stir welding was conducted on Al alloy 6005A-T6 plates of 6 mm thickness. The power input was determined from torque measurements. The effects of advancing speed and rotation speed on total power input were examined. Thermal cycles were mea…

An experimental study was carried out to evaluate the acoustic emission (AE) method as a means of monitoring the welding state and identifying weld defects during the friction stir welding (FSW) process. FSW was carried out on 6061 aluminium alloy p…

An experimental study was carried out to investigate the properties of FSW joints in AA-6056 aluminium alloy, looking at the effects of surface preparation, tool geometry and welding speed and the correlation between these factors. FSW was carried o…