TWI Digital Library

An integrated modelling approach, incorporating coupled process, material response and material performance models, was developed and implemented for use in friction stir welding (FSW) of aerospace structures. The process model employed was a dynami…

An investigation is presented into the development of a flexible 3D friction stir welding (FSW) process capacity incorporating a rail mounted industrial robot to facilitate high production rate repair of aluminium cathodes for electro refining opera…

Technology improvements and process innovations in respect of friction stir welding (FSW) of high temperature materials are reviewed, welding process conditions and mechanical properties of completed welds for various alloys using polycrystalline cu…

Friction stir welding (FSW) trials were carried out for thin HSLA-65 steel plate (6 mm thickness) to evaluate the potential benefits of using induction preheat. Other studies including tool design and multi-run welding are also evaluated as methods …

Friction stir welding experiments were undertaken on Al-Li alloys for application to C919 passenger aircraft fuselage panels, and the microstructure and mechanical properties of the welded lap joints were investigated. The materials comprised 2060-T…

A direct modelling approach ("SAMCEF" software finite element simulation) coupled with an inverse model, based on genetic algorithm optimisation (MAX software), was applied to the friction stir welding (FSW) process for two aluminium alloys (6005A-T…

Artificial Intelligence algorithms based on machine learning approaches have recently found application in joining and welding, e.g., for the optimization of process parameters or the prediction of resulting mechanical properties. The importance of …

Lap joints were fabricated in 2024-T3 aluminium alloy sheets (thickness 1 or 0.6 mm) by refill friction stir spot welding (RFSSW) and the influence of tool sleeve depth on joint quality was investigated. Welding was performed at tool depths of 1.1-1…

A brief review is presented of the state of development of polycrystalline cubic boron nitride (PCBN) tool materials for friction stir welding (FSW) of high-temperature materials (high alloy steels and Ni based alloys) with respect to weld penetrati…

With regard to the application of friction stir welding (FSW) for the butt weld joining of aluminium alloy extrusions into large panels for ship decks and railway carriages, an investigation is presented into the employment of laser ultrasonic testi…

Friction stir welding (FSW) was investigated in aluminium alloys used in aircraft structures. Extruded shapes in alloys 2024 (Al, 4.96%Cu), 7475 (Al, 5.96%Zn, 2.57%Mg, 1.62%Cu) and 7050 (Al, 6.29%Zn, 2.36%Mg, 2.00%Cu) were welded; welds were evaluat…

A coupled numerical and experimental investigation was undertaken to examine residual stress fields and thermal distortion in lap joints made from AA 5754-H22 alloy sheets (thickness 1 mm) by friction stir welding in order to examine the influence o…

WC, 12%Co cemented carbide layers were deposited onto M2 tool steel (0.8-0.88%C, 3.8-4.5%Cr, 4.7-5.2%Mo, 5.9-6.7%W, 1.7-2.1%V) substrates by HVOF spraying and the effect of subsequent friction stir processing (FSP) on bonding strength and cermet coa…

A moving gantry five axis CNC friction stir welding (FSW) machine was developed to facilitate the production of complex curved fuselage components (e.g. stringer and frame) based on third generation 2A97 Al-Li alloys. A ribbed curved component incor…

A friction stir channelling process to promote a distinct material flow was developed, in which a controlled amount of viscoplasticised material from the metal workpiece flows out from the processed zone producing an internal channel without any gap…

Friction stir welding (FSW) experiments were undertaken on AA 5083 aluminium alloys to investigate the influence of process parameters (rotational and travel speeds) and preheating temperature on abnormal grain growth after PWHT. The experimental sp…

Shipbuilding applications of friction stir welding in the production of prefabricated aluminium alloy sections are described. Panels of up to 13 x 16 m, thickness 3-7 mm, may be produced with close tolerances and good surface finish, reducing cost a…

A project to introduce friction stir welding for aluminium shipbuilding in Taiwan is described. The advantages of FSW compared with arc welding for this application are summarised. Stages of the project are outlined, covering work with local tool fa…

Friction stir spot welding experiments were undertaken on AZ31 magnesium alloy (Mg, 3%Al, 1%Zn, 0.2%Mn) sheets (thickness 2 mm) in order to investigate the influence of a flame spray gun rapid preheating process on the microstructures and mechanical…

Friction stir spot welding experiments were conducted on dissimilar metal joints between AA5052 aluminium alloy and three kinds of zinc coated steel, and weldability analysis, microstructure observations and mechanical tests were undertaken. The coa…