TWI Digital Library

A friction stir welding tool with a variable length probe (suitable for variable thickness joints, repairs and circumferential welding) was developed and evaluated for the welding of aluminium alloy 2195. Tapered sheet, of both increasing and decrea…

The repair of friction stir weld defects in aluminium alloy 6061-T6 3 mm thickness sheet (Al, 0.683%Mg, 0.564%Si) by friction stir welding was investigated using artificial defects. The defects were created using an unsuitable pin profile, whilst re…

A refill friction stir spot welding technique was employed to fabricate joints in AA 2014 aluminium alloy (Al, 3.51%Cu, 0.7%Mn) sheets (thickness 2 mm) and the effect of tool rotational speed on microstructure and mechanical properties was investiga…

Numerical simulations and experimental tests were undertaken to visualise material flow and to study the effect of the flow field on the mixing mechanism and particle break-up in friction stir welding of metal matrix composites. A 3D thermo-fluid mo…

An investigation is presented into a methodology for simulating the entire friction stir welding (FSW) process using a hybrid mesh free method on a graphics processing unit (GPU) and its implementation for different FSW applications such as butt joi…

The microstructure and age hardening of friction stir welds in aluminium alloy plate 2014A-T651 (Al, 4.42%Cu, 0.79%Si, 0.62%Mg) and 7075-T651 (Al, 5.99%Zn, 2.72%Mg, 1.46%Cu) were investigated. Single sided butt welds were produced, temperatures bein…

AA 2219 aluminium alloy sheets (thickness 2.5 mm) were joined by friction stir welding (FSW) and an investigation was undertaken into the relationship between joint mechanical properties, the torque generated by the spindle motor and process variabl…

The microstructure and corrosion properties of welded joints in Inconel 22 (Alloy 22 or NO6022) made by friction stir welding (FSW) were investigated. Bead-on-plate welds were produced in Alloy 22 (59.6%Ni, 13.43%Mo, 0.22%Cr, 3.29%W, 3.17%Fe, 0.84%C…

In relation to the requirement for automatic inspection of weld quality during the friction stir welding (FSW) process, the "MonStir" process monitoring system was developed to analyse measured process forces and their frequency spectra, and an inve…

In relation to the occurrence of abnormal grain growth in aluminium alloy spun formed dome development using friction stir welded (FSW) blanks, an investigation is presented into tensile tests performed on two AA 2195 (Al, 4%Cu, 1%Li) FSW parameter …

Several kinds of Co-based alloys with different mechanical properties (e.g. high temperature strength, hardness, wear resistance and gamma-solvus temperature) were designed for friction stir welding (FSW) tool applications by varying chemical compos…

Dissimilar lap joints between AA 6061-T6 (Al, 1.01%Mg, 0.59%Si) and A356 (Al, 7.02%Si) aluminium alloys were fabricated by friction stir welding (FSW) and the influence of process conditions on joint microstructure evolution and mechanical propertie…

An investigation is presented into the effects of process parameters on weld quality and defect generation (hooking defects, kissing bonds and top plate thinning) in 7075-T6 aircraft stringers (thickness 1.5 mm) lap-joined on 2024-T3 skins (thicknes…

Low temperature friction stir welding (FSW) was employed to join three types of carbon steels and the effects of carbon content, process conditions and phase transformations on the microstructure and mechanical properties of the welded joints were i…

A phenomenologically based semiphysical modelling approach was employed to develop a process window for friction stir welding (FSW) of AA 2024-T3 aluminium alloy, incorporating simulation of the filling level of the welded joint as a means to determ…

The viscosity of aluminium alloy 6061-T6 was determined to obtain data necessary for the modelling of friction stir welding. A friction stir welding tool with a 5 mm diameter pin was plunged into an alloy disc (tool speeds 900-1500 rev/min, plunge d…

This paper describes the goals and initial progress of the research project titled "qualification of micro friction stir spot welding for cell-internal contacting of large-format battery cells in a battery production environment (μKoBatt)", which…

Friction stir butt welding experiments were conducted on S45C medium carbon steel sheets (thickness 1.5 mm) under various conditions and the microstructure and mechanical properties of the welded joints were investigated. Single run butt welding was…

Three recently published finite element studies, modelling friction stir welding (FSW) of different aluminium alloys, were reproduced using ABAQUS software and the results were comparatively assessed. The models considered were as follows: heat tran…

The tensile and bend properties of friction stir welded butt joints in aluminium alloys 2024-T3, 6013-T6 and 7475-T76 were determined, including welds in 2024 and 7475 subjected to PWHT. The ultimate tensile strength, proof stress at 0.2% strain, an…