TWI Digital Library

In this study, the mechanical properties and metallurgical joining interface of aluminum alloy and various strength steel joints by scrubbing refill FSSW (Sc-RFSSW) were investigated. It was shown that Sc-RFSSW provides higher joint strength than co…

An investigation is presented into the development of the stationary shoulder self-reacting pin tool (SSSRPT) as a friction stir welding variant and the application of the tool to fabrication of butt joints in sheets (thickness 4 mm) of A6N01 alloys…

A refill friction stir spot welding (RFSSW) process with a short welding cycle time was employed to fabricate welded joints in thin gauge AA 6111-T4 aluminium alloy sheets (thickness 0.9 mm) and the mechanical properties of the joints were investiga…

Defects and their mitigation associated with the fabrication of fluid-cooled aluminium alloy heatsinks for electronic applications are discussed. The heatsink consisted of an aluminium alloy 6063 substrate (310 x 300 mm) with a series of rectangular…

Arcan tests (pure tensile, pure shear and mixed tensile/shear loads) were performed on parent material (6056-T78 aluminium alloy) and friction stir welded (FSW) specimens for comparison purposes and to assess the capability of strain field measureme…

Stationary shoulder friction stir welding (SSFSW) and conventional FSW experiments were undertaken on AA 7050-T7651 alloy plates (thickness 6.3 mm) to demonstrate the advantages of SSFSW with respect to surface finish, thermal profile symmetry, HAZ …

An algorithm and procedure for controlling process zone temperature during friction stir processing are presented. The approach is based on the correlation between weld zone temperature with spindle power. A simplified thermal balance model of the w…

A methodology is presented to define conical tool geometry and process parameters for friction stir welding (FSW) of thin plates. A calculation algorithm integrating a basic thermal model, tool geometry and process kinematics is proposed, the proces…

In relation to the development of "AIRWARE" technology based on Al-Cu-Li alloys for aircraft structural parts, a report is presented into the friction stir welding (FSW) of "AIRWARE" 2050 alloys, mechanical characterisation of welded joints, and ind…

A conceptual model was developed to describe the relationship between process variables and physical properties such as spindle torque, heat generation and workpiece temperature distribution for friction stir welding of aluminium alloys. The materia…

Thermodynamic modelling and experimental measurements were employed to investigate the influence of intermetallic compound formation on the shear strength of dissimilar joints between an aluminium alloy and ultra-high strength steel fabricated by fr…

The effects of friction stir welding (FSW) on the microstructure, hardness, residual stress state and grain distribution of 2124 Al-SiC composite alloy were investigated. The composite was of AMC225xe aerospace AW2124 alloy reinforced with 25% SiC p…

Ni3Al/Ni3V dual two-phase intermetallic alloys, incorporating Ta and Re additions, with enhanced high-temperature strength and hardness, were developed for friction stir welding tool applications and applied to fabricate butt welds in SUS 430 steel …

Friction stir welding (FSW) experiments were conducted on X52 and X60 pipeline steel specimens (outer diameter 324 mm, wall thickness 6.35 mm) and weldment integrity was evaluated by metallography, NDE and mechanical properties characterisation. Wel…

Two common approaches to describe kinematics in simulations of the friction stir welding (FSW) process, the Lagrangian representation and the Eulerian representation, were compared using "ABAQUS/Explicit" and "FLUENT" software programs, and the infl…

The details and methodology of an automatic path planning system for friction stir processing (FSP) of castings are presented, incorporating the means by which operator input is minimised, the limitations and challenges of the automatic programming …

Friction stir spot welded joints in aluminium alloy 6061-T4 were studied. Sheet of 1, 1.5, 2, and 3 mm thickness was friction stir welded to sheet of 3 mm thickness, using welds of 8-18 mm in length (equivalent in area to circular resistance spot we…

Development work by TWI on behalf of the Swedish Nuclear Fuel & Waste Management Co. for the EB and friction stir welding of lids onto Cu radioactive waste disposal canisters (1050 mm diameter, 50 mm wall thickness) is reviewed. In 1986, when th…

Friction stir welding was evaluated as a cheaper alternative to the use of fasteners for the joining of lap joints of the aluminium alloy 7075-T351 motor thrust frame of the Ariane 5 rocket. In initial trials to optimise the tool design for lap join…

Details are reported of application of friction stir welding (FSW) to manufacture of double skin bodies of railway carriages for commuter lines in Japan. A "defect free" FSW process is used to weld double skin panels of length 25 m using hollow extr…