TWI Digital Library

A fully coupled thermomechanical formulation was proposed for the numerical modelling of friction stir welding (FSW) to facilitate the efficient simulation of different types of material flows and accurate computation of the resulting thermomechanic…

A 3D computational fluid dynamics model was developed to conduct numerical simulations of heat generation, material flow and temperature profiles during reverse dual-rotation friction stir welding, a process variant in which the tool pin and the ass…

SiC particle reinforced 2124Al metal matrix composite (MMC) plates (thickness 8 mm) were joined by friction stir welding (FSW) and the relationship between process parameters, weld defect formation and joint mechanical properties was investigated. T…

With regard to the application of wear resistant surface layers on chosen substrates, an investigation is presented into the deposition of cermet (WC, 10%Co, 4%Cr or Cr3C2-NiCr) and oxide (Al2O3) coatings onto AA 5083 aluminium alloy substrates by c…

The feasibility of friction stir welding (FSW) for welding aluminium alloy 7020, used for the construction of light armoured fighting vehicles, was investigated and compared with MIG welding. Two joint configurations were tested: butt welding in 100…

AA 2219-T87 (Al, 5.8-6.8%Cu, 0.2-0.4%Mn) aluminium alloy plates (thickness 8 mm) were joined by friction stir welding (FSW) and their microstructure, mechanical properties and corrosion behaviour were investigated. FSW experiments were conducted usi…

Friction stir welding (FSW) experiments were undertaken on stacked laminates of pure copper and 60/40 brass (60%Cu, 40%Zn) to investigate material flow patterns and microstructural changes during welding. FSW was conducted using a threaded MX Tri-fl…

With regard to the dependence of shoulder friction generation in bobbin friction stir welding on the interference (compression) between the substrate and the tool, an investigation was undertaken into the effects of different interference (compressi…

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…

The mechanical properties and microstructures of friction stir butt welds in 6.4 mm and 12.7 mm thickness quenched and tempered martensitic steel plate were compared with those of GMA butt welds in the same parent metal. The friction stir welds in t…

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…

A friction melt bonding process was employed to fabricate dissimilar lap joints between ultralow carbon (0.01%C, 0.14%Mn) or dual-phase DP600 (0.08%C, 1.51%Mn, 0.35%Cr, 0.06%Mo) steel grades and 1050, 2024 or 6061 aluminium alloys and the microstruc…

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…

A plastic replication technique was employed to investigate surface crack initiation and growth in 2024-T351 Al alloy friction stir welded (FSW) joints during fatigue bending tests. Fatigue failure mechanisms were examined, and a modified Hobson-Bro…

Fusion devices include plasma facing components consisting of copper-based heatsinks embedded with cooling channels to handle the high operational heat loads. Stationary shoulder friction stir channelling (SSFSC), trademarked as Coreflow®, is a …

Friction stir welding was employed to fabricate butt joints in Ti-6%Al-4%V sheets (thickness 2 mm) and the effect of process parameters on joint microstructure and plastic deformation behaviour was investigated. Welding experiments were conducted at…

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-…

A Granular Computing (GrC) Neural-Fuzzy (NF) modelling approach that can learn relational data descriptions from a minimum number of experimental data is proposed for finding optimal process operating windows in friction stir welding (FSW). Research…

The relationship between microstructure and corrosion of friction stir welded joints in aluminium alloys 2024-T351 (Al, 4.43%Cu, 1.42%Mg, 0.61%Mn) and 7010-T7651 (Al, 5.92%Zn, 2.11%Mg, 1.68%Cu) was investigated. Plate of 6.35 mm (0.25 in) thickness …