TWI Digital Library

Dissimilar lap joints between aluminium alloys and various steel grades were fabricated by friction stir welding (FSW), FSW tool wear was measured and a phenomenological law was developed with respect to pin length reduction over weld length to repr…

A controller was developed and tested for the friction stir welding of copper canisters, used in the nuclear industry. The cascaded loop controller determines the power input requirement and tool temperature to achieve a stable, robust and repeatabl…

Butt joints were fabricated in sheet specimens of 2017A-T451 alloys (Al, 4.14%Cu) and cast plates of Al, 8.6%Si, 0.31%Mg by friction stir welding (FSW) and their microstructure and mechanical properties were investigated. Welding experiments were co…

Models to predict the precipitate and grain size evolution in AA7449 aluminium alloy friction stir welds are presented and compared with experimental data. Bead on plate welds on 3.2 mm thickness sheets of composition Al, 8.4%Zn, 2.1%Mg, 1.8%Cu were…

A comparative study was undertaken of three different machine types, a modified high payload robot, a CNC milling machine and an ESAB "SuperStir" FSW machine, in terms of their capability for FSW of various aluminium alloys using identical process p…

Friction stir welding was employed to fabricate welded joints in AA 7475-T7351 aluminium alloy plates (thickness 6.35 mm) and the effect of kissing bond defects on fatigue life and other mechanical properties was investigated. Welded test specimens …

An experimental investigation was undertaken to examine how tool pin induced material flow and intermetallic growth conditions affect the formation of discontinuity during friction stir lap welding of dissimilar Al-Cu joints. The materials comprised…

Friction stir welding experiments were undertaken on 2195-T8 (Al, 3.99%Cu, 1.09%Li) alloy sheets (thickness 5 mm) and the weldability, microstructure and mechanical properties of the fabricated butt joints were investigated. Welding was performed us…

A two-step modelling procedure, consisting of a thermo-fluid model and a thermo-mechanical model, was employed to predict temperature, flow and residual stress fields around the workpiece block, steel backing plate and tool in friction stir welding …

A friction stir welding tool with a variable length probe (suitable for variable thickness joints, repairs and circumferential welding) was developed and evaluated for the welding of aluminium alloy 2195. Tapered sheet, of both increasing and decrea…

An economic analysis was undertaken to compare the costs of onshore and offshore pipeline construction scenarios for welds made using friction stir welding (FSW) and conventional mechanised MIG/MAG welding. Pipe diameters of 1067 and 305 mm were sel…

Numerical simulations and experimental measurements were undertaken to study the temperature fields developed during friction stir welding (FSW) of AW 5083 (Al, 4-4.9%Mg, 0.25%Mn) alloy plates (thickness 10 mm). Welding was conducted at a rotational…

AZ31 magnesium alloy sheets (thickness 3 mm) were joined by TIG welding and the effect of two run rapid cooling friction stir processing (RC-FSP) on welded joint microstructure and mechanical properties was investigated. TIG welding was undertaken a…

Dissimilar butt joints between die-cast ADC12 aluminium alloy (Al, 11.53%Si, 2.02%Cu) and S45C carbon steel (0.46%C, 0.64%Mn, 0.12%Cu) were fabricated by friction stir welding and their static strength and fatigue properties were investigated. Weldi…

With regard to the use of copper canisters for the storage of spent nuclear fuel, an investigation is presented into a cascade controller to maintain probe temperature and to control power input and tool depth during friction stir welding procedures…

The friction stir weldability of the dissimilar materials copper and aluminium alloy was studied, assessing the effects of different process parameters (rotation and traverse speeds, rotation direction (Cu or Al on advancing side), displacement and …

Kahn notched tear tests and fractography were employed to investigate variations in toughness and fracture mode across the weld zones in friction stir welded AA 7449 plates (thickness 40 mm) in the TAF (temper for age-forming) condition. Welding was…

A report is presented into the development of a refill friction stir spot welding (FSSW) robot system, performance evaluation with respect to FSSW of aircraft aluminium alloys, and fabrication of full-scale aircraft production components. The FSSW r…

Friction stir welding (FSW) experiments were undertaken on type 304 austenitic stainless steel (18-20%Cr, 8-10.5%Ni) under various process conditions by changing the heat input, and the microstructure and mechanical properties of joints obtained at …

Dissimilar butt joints between aluminium alloys and steel or an AZ91 magnesium alloy (Mg, 9.39%Al, 0.85%Zn) were fabricated by ultrasound enhanced friction stir welding (USE-FSW) and their microstructure, mechanical and corrosion properties were inv…