TWI

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…

With regard to the development of 9%Ni steels for cryogenic applications, an investigation was undertaken into the metallurgical weldability of ASTM A553 Type I steel (0.08%C, 0.73%Mn, 9.4%Ni) joined by double-sided two-run friction stir welding (FS…

A slide style presentation giving a market review of FSW, challenges for FSW users and process enhancements. The development of equipment and methods for floating bobbin tool FSW and stationary shoulder friction stir welding is outlined. Lifetimes o…

Similar and dissimilar friction stir welds (FSW) were performed between 2014-T6 and 6061-T6 aluminium alloy sheet (4.70 mm thickness). Weld speed of 450 and 90 mm per minute were used to produce welds described as cold and hot welds respectively. Ad…

Friction stir spot welding (FSSW) experiments were undertaken to fabricate dissimilar metal joints between aluminium and light metals such as magnesium and titanium, and the microstructure and mechanical properties of the weldments were investigated…

The application of friction stir welding (FSW) to the fabrication of copper backing plates of thickness 6 mm was investigated. The welding conditions, FSW machine development, and mechanical and metallurgical properties of friction stir welded joint…

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…

Friction stir lap welding of aluminium alloy to magnesium alloy was investigated, emphasising the tensile strength, fracture location in the joint and microstructure evolution in the weld under different welding heat inputs. Dissimilar joints betwee…

A two-run friction stir welding process was employed to fabricate butt joints in API 5L X80 pipeline steel (0.08%C, 1.86%Mn, 0.16%Cr, 0.01%Ni, 0.18%Mo, 0.03%V, 0.06%Nb) plates (thickness 12 mm) and fracture toughness was determined in the parent met…

With regard to the development of aluminium military vehicles, a report is presented into production level single run friction stir welding (FSW) process parameters for thick plate samples (thickness 12.7-40.6 mm) of 5083, 5059 and 2139 aluminium al…

Friction stir welding experiments were undertaken on commercial SPF (superplastic forming) AA 5083-H19 (Al, 4.43%Mg) and AA 2004 (Al, 6.05%Cu) aluminium alloys, and the effects of tool size, geometry and primary process variables on microstructure a…

The friction stir welding (FSW) manufacturing technology of large aluminium extrusions for rail, automotive and aerospace applications was optimised. Tensile strength, impact value, hardness and microstructure were investigated in friction stir weld…

Advances in low cost, rapidly re-configurable fixturing and support tooling for the production of complex curvature parts by friction stir welding are described. An Intelligent Friction Stir Welding (IFSW) path planning algorithm developed by the So…

The development of cryogenic tank domes for gas tanks for carrier rockets using friction stir welding (FSW) and high strength aluminium alloys of the 2xxx series is outlined. The verification of an existing NC-controlled milling machining centre (Ca…

Friction stir processing (FSP) experiments were undertaken on three Ni-based alloys (Alloy 625 (Ni, 21.6%Cr, 8.6%Mo, 3.7%Fe), Alloy 718 (Ni, 23.7%Fe, 18.1%Cr, 3.1%Mo, 1%Ti) and Hastelloy X (Ni, 21.3%Cr, 19.2%Fe, 8.3%Mo)) using a W-Re tool, process p…

Friction stir spot welding (FSSW) experiments were undertaken on sheet specimens of similar and dissimilar combinations of AA 2024-T3 (thickness 1.27 mm), AA 2024-O (2.2 mm) and AA 7075-T6 (1.27 mm) aluminium alloys under various process conditions,…

Ultrafine grained test pieces of aluminium, copper and steel produced by the accumulative roll bonding process were friction stir butt welded at various revolutionary pitches, and the microstructures and mechanical properties (tensile strength, Vick…

Thick section friction stir welds were made in 25.4 mm (1 in) 5083-H131 and in 18.4 mm 2195-T8P4 aluminium alloy plates by single-pass friction stir welding (FSW) using new welding tool designs. The alloys are used for aerospace applications. The sh…

Friction stir welding of UK Ministry of Defence Def Stan 95-22 7017 aluminium alloy (Al, 4.5%Zn, 2.0%Mg) armour plate was evaluated by studying the mechanical properties and cracking of welded joints. Initially plate of 10 mm thickness, locally redu…

A brief review is presented of the RIFTEC welding job shop, a major supplier for friction stir welded components in Germany, and Hammerer Aluminium Industries (HAI) in Austria and some of their applications to railway, automotive and electronic indu…