TWI Digital Library

With regard to the requirement to produce friction stir welded (FSW) lap joints with strength and fatigue properties suitable for commercial regional aircraft, work undertaken by MTS Systems and Bombardier Aerospace to develop pin tools and corrosio…

Preliminary results from a 3-dimensional heat and material flow computer simulation program for friction stir welding are given and compared with experimental observations. The simulation is based upon solutions of Navier-Stokes equations and nonlin…

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…

A techno-economic assessment study was undertaken with respect to the feasibility of the friction stir welding (FSW) technique for microalloyed DH36 grade shipbuilding steel (0.11%C, 1.48%Mn, 0.02%Nb, 0.02%Al) plates (thickness 6 mm). Single sided f…

A coupled Eulerian-Lagrangian approach with Abaqus v.6.14 finite element software was employed to model the whole friction stir welding (FSW) process within one continuous model and results for temperature fields, surfaces, weld formation and proces…

The fatigue performance of friction stir welded butt joints in 2024-T3 aluminium alloy plate (thickness 6.35 mm) was investigated by adopting six different tool designs and using a design of experiments analysis over a wide range of process paramete…

In relation to the generation of oscillating process forces during friction stir welding (FSW), hypotheses covering phenomena that can lead to dynamic effects were formulated and a finite element model of the process-machine-system (containing both …

Spot welds were fabricated in DC01 mild steel and HC 420-LA high strength steel sheets (thickness 1 mm) by friction stir spot welding (FSSW) using various pinless tools and process parameters, and thermographic analysis together with microstructural…

Various dissimilar butt joints were fabricated between 2017A-T451 (Al, 4.14%Cu, 0.72%Mg), 6082-T6 (Al, 1.03%Mg, 0.92%Si) and AlSi9Mg (Al, 8.6%Si, 0.31%Mg) aluminium alloys by friction stir welding using a high pin tool rotational speed (1400 or 1800…

The tool workpiece thermocouple (TWT) temperature measurement method was applied for optimisation of the initial welding phases (plunge and dwell) in conventional FSW (friction stir welding) and FSSW (friction stir spot welding), and an analysis of …

Dissimilar joints between half-hard phosphorus deoxidised copper and annealed wrought AA 5083 alloys (Al, 4-4.9%Mg, 0.4-1%Mn) were fabricated by friction stir spot welding and the influence of process parameters on joint microstructure and mechanica…

An investigation is presented into the occurrence of a grey line in x-ray diffraction of friction stir welded joints of AA 2024-T62 aluminium alloys, and its influence on mechanical and fatigue properties. Welding in 2 mm sheet was performed using a…

The velocity field in the shear layer surrounding the tool/matrix interface in friction stir welding (FSW) was used to characterise material flow and was investigated by x-ray/computational tomography (CT) marker material experiments as well as anal…

Friction stir welding experiments were conducted on plate specimens (thickness 6 mm) of AA 2219 aluminium alloys (Al, 6.48%Cu, 0.32%Mn) and the crystallographic texture and deformation behaviour of the weld zones (HAZ, thermomechanically affected zo…

An experimental procedure based on a Gleeble 3500 thermomechanical testing system was developed to investigate hot deformation parameters in the high temperature range for application to friction welding related processes. Experiments were conducted…

A review is presented of the application of CFD (computational fluid dynamics) to numerical modelling of the friction stir welding (FSW) process, incorporating coupled physical phenomena such as heat generation, heat transfer and metal flow. Issues …

An experimental canister welding machine was developed in order to evaluate FSW as a method of welding the copper canisters used in the long term storage of nuclear waste. Preliminary trials involved the development of a machine with sufficient stif…