TWI Digital Library

With regard to the development of additive friction stir deposition (or MELD) as an additive manufacturing process, a mesh-free coupled thermomechanical approach was employed to model MELD by invoking smoothed particle hydrodynamics to discretise th…

Friction stir welding (FSW) experiments were undertaken on Invar 36 alloy (Fe,36%Ni) sheet specimens (thickness 3 mm) and the microstructure evolution and recrystallisation mechanism were investigated. Bead-on-plate FSW was performed using a polycry…

Dissimilar joints between wrought 5083 and 6111 aluminium alloys and between AZ31 magnesium alloy and 6111 were fabricated by friction stir welding and their microstructure and mechanical properties were investigated. The starting materials were 508…

To overcome the limitations associated with conventional friction stir welding, particularly for complex shaped large structures, the bobbin tool technique was developed and demonstrated on various aluminium alloys (4-15 mm thickness range), the tec…

Weld production tests were conducted using friction stir welding (FSW) and MIG processes for the production of aluminium panels. Production times were measured using a 2 m long double-skinned EN AW 6005 A-profile joint as the basic unit. Welding spe…

The thermal stability of the microstructure in the plastically deformed region of aluminium alloy friction stir welds was investigated. Alloys 6082-T6 (Al, 0.62-0.70%Mg, 0.95-1.05%Si, 0.50-0.57%Mn, 0.15-0.23%Fe) and 7108-T79 (Al, 5.20-5.70%Zn, 0.70-…

Aluminum 6xxx extrusions are commonly joined with either friction stir welding (FSW) or fusion welding into large-sized assemblies. The assemblies are typically deployed to service in as-welded condition. Mechanical performance of naturally aging we…

A technique was developed to fill the exit hole during the retraction phase of a friction stir welding (FSW) sequence which, by using existing equipment functionality and designing a hollow FSW tool, syringe-type delivery system and pre-loaded alumi…

Friction stir welding (FSW) was employed to undertake lap joining of very thin sheets (thickness 1 mm) of aluminium alloys and a structural steel using different tool geometries and a wide range of process parameters, and the microstructure and mech…

A scanning nonlinear acoustic NDT method was employed to detect the presence of kissing bonds in a friction stir welded 2000 series aluminium alloy and experimental results were validated using coupons taken from the scan area and inspected by optic…

AZ31 magnesium alloy sheets (thickness 4 mm) were joined by friction stir welding under process conditions with and without a heat sink, and the residual stress distribution in the joints was investigated by a hole drilling method according to the A…

With regard to the application of friction stir welding (FSW) of ultra thin aluminium sheets (thickness less than 1 mm) to electronic packaging and micromechanical component joining, an investigation is presented into fixturing, process parameter an…

AA 6061-T651 aluminium alloy (Al, 0.81%Mg, 0.53%Si) plates (thickness 9.5 mm) were joined by friction stir welding (FSW) and the influence of FSW tool eccentricity on material flow and welded joint mechanical properties was investigated. Welding was…

Friction stir welding (FSW) was employed to fabricate butt joints in AW 5083 (Al, 4-4.9%Mg, 0.4-1%Mn) aluminium alloy plates (thickness 10 mm) and the influence of process parameters and tool geometry on the character and quality of welded joints wa…

Friction stir processing (FSP) trial experiments were conducted on superplastic Zn, 21.1%Al eutectoid alloys using a modified milling machine and the results were evaluated in relation to residual microstructures, mechanical properties and damping c…

Friction stir processing (FSP) was employed for grain refinement and strengthening of cast Mg, 5.9%Y, 2.6%Zn alloys and the microstructure and mechanical properties of the processed material were investigated. Specimens comprised plates (thickness 1…

A Lagrangian particle model based on the SPH (smooth particle hydrodynamics) method was developed for friction stir welding (FSW) of similar and dissimilar materials by disregarding elastic deformation and describing plastic deformation by the Johns…

In relation to the development of a friction stir welding (FSW) process to seal copper canisters for nuclear fuel waste, an investigation was undertaken into material and heat flow in FSW copper plates (thickness 50 mm) by inserting brass rods into …

Friction stir processing (FSP) was employed to stir electroless copper coated SiC particles with a core shell structure to produce SiC/Cu particle reinforced aluminium matrix composites in the stir zone of AA 6061-T651 aluminium alloy plates with th…

Friction stir spot welding (FSSW) experiments were undertaken on sheet specimens of similar and dissimilar combinations of AA 2024-T3 (thickness 1.27 mm), AA 2024-O (2.2 mm) and AA 7075-T6 (1.27 mm) aluminium alloys under various process conditions,…