TWI

AA 2219 aluminium alloy sheets (thickness 2.5 mm) were joined by friction stir welding (FSW) and an investigation was undertaken into the relationship between joint mechanical properties, the torque generated by the spindle motor and process variabl…

A kinematic approach is presented for modelling the friction stir welding process and the relationship between tool geometry and process parameters. The model was used to describe the correlation between features of the weld nugget, process paramete…

Vertical and angular truss extrusions made from 6082-T6 aluminium alloy (Al, 0.7-0.74%Mg, 1.04-1.14%Si, 0.53-0.54%Mn) were friction stir welded in a half-overlap configuration to fabricate panels for marine applications and their fatigue performance…

A cantilever type rotary bending fatigue testing machine with high speed loading capability was employed to investigate the high cycle fatigue properties of the stir zone, thermomechanically affected zone and HAZ in friction stir welded joints of va…

Friction stir welding experiments were conducted on AA 2024-T3 Al-Cu-Mg alloys to investigate the influence of backplate design on joint microstructure and mechanical properties. Trials were performed using three specially designed backplates based …

Periodic material phenomena around a threaded pin in friction stir welding (FSW) were investigated with a fully transient thermomechanically coupled numerical simulation, in which the transient motion of the threaded pin was included in the computat…

The microstructure and age hardening of friction stir welds in aluminium alloy plate 2014A-T651 (Al, 4.42%Cu, 0.79%Si, 0.62%Mg) and 7075-T651 (Al, 5.99%Zn, 2.72%Mg, 1.46%Cu) were investigated. Single sided butt welds were produced, temperatures bein…

An experimental and numerical analysis of the wear of a polycrystalline boron nitride (PCBN) friction stir welding (FSW) tool is overviewed as presentation slides. Topics highlighted include: FSW plunge trials of EH46 shipbuilding steel at a plunge …

The integration of friction stir welding (FSW) into the manufacturing sequence of spinformed domes of aluminium alloys is presented in terms of its optimisation and the specific iterations required with the prior and follow-up procedures of the manu…

Friction stir spot welding (FSSW) was employed to fabricate dissimilar lap joints between a 6000 series aluminium alloy (Al, 1%Si, 0.5%Mg) in the T4 condition and SPCC mild steel (0.05%C, 0.01%Si, 0.14%Mn) without formation of intermetallic compound…

An investigation is presented into the use of a friction stir welding/forging process to fabricate tee and I-beam shapes with integral radial shaped fillets, the optimisation of process parameters for different alloys and shapes, and the results of …

With regard to the application of friction stir welding (FSW) to the production of launcher tanks holding cryogenic liquids, an investigation was undertaken to establish a robust and industrialised FSW process for AA 2219 alloys in T87 and T851 cond…

Friction stir welding (FSW) experiments were undertaken on sheet specimens (thickness 5 mm) of 5454-H111 aluminium alloys and the relationships between process forces, spindle power and tool geometry were investigated. Twelve FSW tools with specifie…

A friction stir welding (FSW) methodology incorporating laser tracking and constant force control technologies was developed in order to fabricate large, thin-walled aircraft floor structures. The material chosen for study comprised sheet specimens …

The bobbin tool or self-reacting tool variant of the friction stir welding process was investigated on butt joints of various 2000 series aluminium alloys for aircraft fuselage applications; welding feasibility tests were conducted in pin length con…

With regard to the development of dissimilar aluminium-steel joint fabrication for automotive applications such as body-in-white, an investigation incorporating experiment and numerical simulation was undertaken to examine the dissimilar friction st…

In relation to the challenges involved in temperature data acquisition and transmission associated with rotation of the friction stir welding (FSW) tool, an investigation is presented into a wireless temperature monitoring system based on thermocoup…

In relation to the requirement for automatic inspection of weld quality during the friction stir welding (FSW) process, the "MonStir" process monitoring system was developed to analyse measured process forces and their frequency spectra, and an inve…

Friction stir welding (FSW) tools, equipment and auxiliary devices were developed for application to heavy section aluminium alloy plate (thickness 40-70 mm), and the microstructure and mechanical properties of welded joints fabricated by the proced…

Electron backscattering diffraction (EBSD) was employed to examine the grain refinement during rapid cooling friction stir welding of commercially pure copper sheets (thickness 2 mm) and the application of a liquid CO2 cooling technique to reduce th…