TWI Digital Library

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…

The feasibility of short-cycle friction stir spot welding for joining thin sheet aluminium alloys and steels, both galvanised and ungalvanised, was evaluated. Welds were made between 6111-T4 AlMgSi alloy (Al, 0.75%Cu, 0.25%Fe, 0.75%Mg, 0.2%Mn, 0.69%…

Different aluminium alloys were joined by friction stir welding (EN AW-5754-H14 to sheets of the same material, extruded profile EN AW-6063-T6 sheets to high pressure die cast EN AC-46000) and characterised by x-ray and microscopy studies, and the m…

Dissimilar lap joints between AlSi10MgMn aluminium alloy sheets (thickness 3 mm) and Al-Si coated Usibor 1500 22MnB5 hot stamped boron steel sheets (thickness 1.8 mm) were fabricated by friction stir spot welding (FSSW) under different processing co…

Two abutting plates (thickness 6 mm) of Al 6061-T6 and cold rolled AISI 1018 mild steel were friction stir welded along the butt joint with the steel and aluminium, respectively, on advancing and retreating sides, and the relationship between proces…

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 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…

Friction stir welded joints in 2024-T351 Al-Cu-Mg alloy were subjected to fatigue testing to evaluate the suitability of this welding process for aircraft manufacture. Aluminium alloy (Al, 3.8-4.9%Cu, 1.2-1.8%Cu, 0.5%Si, 0.5%Fe, 0.2%Zr) of 6.35 mm (…

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…

Fatigue testing was performed on welds joining AA2024 (AI4.5Cu1.4 Mg0.5Mn) alloy to TI6Al4V alloy by having AA100 strip as an interlayer utilizing friction stir lap welding (FSLW). During FSLW, the pin bottom was aimed not to touching the Ti6Al4V pl…

A modified Gleeble hot torsion test was used to simulate the stir zone microstructures in types 304L and 310 stainless steels obtained during friction stir welding (FSW). A Gleeble 3800 with a torsion mobile conversion unit was used to perform the t…

A short review is presented of the development of a friction stir welding process for steel and other hard metals using W-Re tool materials to produce repeatable, thick-section welds with minimal tool deformation. Issues discussed include: W, 25%Re …

An investigation is presented into the fatigue characteristics of friction stir welded (FSW) lap joints made from artificially aged Al alloy 6082 (Al, 0.6-1.2%Mg, 0.7-1.3%Si) using a tool based on the "Triflute" concept with either convex or concave…

A 16-run screening design of experiments (DOE) was conducted to analyse the effects of nine factors during friction stir welding on process forces, temperatures and shoulder depth. The factors were spindle speed, feed rate, plunge depth, pin length,…

Friction stir linear welding and friction stir spot welding techniques were employed to fabricate robust and reliable welded joints for automotive front end substructure applications between AA6022-T4 aluminium alloy and AM60B magnesium alloy sheets…

A numerical and experimental study was undertaken to investigate the mechanism of swing friction stir spot welding (FSSW) and the effects of swing length and weld direction on the joint strength. Coupons were taken from a commercial A6022-T4 alumini…

Carbon nanotube reinforced AA 6063 aluminium alloy (Al, 0.65%Mg, 0.34%Si) metal matrix composite (MMC) sheets (thickness 1.8 mm) were joined by friction stir welding (FSW) and experimental studies were undertaken to examine the MMC weldability as we…