TWI Digital Library

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…

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…

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 …

Friction stir welding (FSW) experiments were undertaken to investigate the feasibility of joining a metal matrix composite (MMC), comprising an AA 2124 matrix and 25 vol.% SiC particles, to itself and to a monolithic alloy (AA 2024-T3), and the micr…

Friction stir welding of DH-36 mild steel sheet was evaluated for shipbuilding applications. Butt welds were prepared in sheet of 4.6 mm (0.18 in) thickness using an unthreaded tool (W, 25%Re) rotating at 400 or 500 rpm and travelling at 203 mm/min …

A method was developed to integrate basic force control functionalities into a CNC milling machine for friction stir welding (FSW) by using a standard CNC controller, optimum control parameters for various FSW conditions were identified and the forc…

Based on lessons learned from the MegaStir research programme devoted to friction stir welding (FSW) of high temperature alloys and with the aim of producing high quality, defect free welded joints while maximising tool life, a report is presented i…

Friction stir welding (FSW) is a solid-state joining method, being well-known to be suitable particularly in joining of aluminum in all alloy and manufacturing forms. The technological advantages of FSW can be also expanded to high-strength steel ma…

The forces exerted on the pin of a friction stir welding tool with a variable length pin (retractable pin-tool) were measured whilst welding aluminium alloy 2195 plate of 8.4 mm thickness, to develop a closed loop control system. Forces were measure…

The weldability of magnesium alloys by friction stir welding was studied using three die-cast alloys of thickness 6 mm (AM50 and AM60 Mg-Al-Mn alloys; AZ91 Mg-Al-Zn alloy) and one wrought alloy of thickness 6.4 mm (AZ231 Mg-Al-Zn alloy). Surface app…

Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process dev…

Friction stir welding (FSW) has been used to weld aluminum alloys such as 7075 to 7075, which is considered not weldable by most other methods. In this application FSW was used to join two dissimilar aluminum alloys 7075 and 6N pure copper in a lap …

An extensive study of friction stir welding (FSW) of HSLA-65 steel plate (thickness 6 mm) was undertaken, incorporating defect-free friction stir butt welding at a travel speed of 3.4 mm/s, the achievement of low/no distortion FSW by employing appro…

A methodology incorporating friction stir processing (for plasticising) and friction stir welding (for joining components) was developed to fabricate T-shaped copper conductor rails. Experiments were undertaken on copper plate specimens (thickness 8…

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…

The joining of hot rolled aerospace quality AZ31B-H24 magnesium alloy (Mg, 2.5-3.5%Al, 0.7-1.3%Zn, 0.2-1.0%Mn) sheets (thickness 4.95 mm) was investigated using an MTS ISTIR friction stir welding (FSW) machine, the quality of the butt joints produce…

Fatigue tests were performed using lap-shear specimens of friction stir spot welded Al, 0.8%Mg, 1%Si alloys. Sheet specimens (thickness 2 mm) were subjected to PWHT of solution treatment and/or ageing. Weld zone microstructure was observed by SEM. F…

The design, construction and use of a purpose-built friction stir welding machine for the welding of 15.9 mm (0.625 in) thickness, 1.88 m (74 in) long aluminium alloy 6061-T6 plate and extruded sections to form the side panels of a laser system is d…

With regard to the fabrication of closure welds for used fuel containers, a series of experiments was undertaken to demonstrate the feasibility of creating defect-free partial penetration welds by friction stir welding (FSW) in A516 Grade 70 steel (…

The application of suitable friction stir welding (FSW) tools and procedures to common structural geometries in industry, with emphasis of FSW of hard metals including steel, titanium and nickel based alloys in butt, T-joint, corner joint and circum…