TWI Digital Library

With regard to the problem of parameter development for friction stir welding (FSW) of workpieces with 3D joints, a self-tuning algorithm is presented based on the tool-workpiece thermocouple (TWT) method for temperature measurement to facilitate th…

Rotary friction welding was employed to fabricate joints between an ASTM A36 steel pipe (0.11%C, 0.2%Si, 0.92%Mn, 0.02%Cr, 0.02%Nb, 0.03%Al) and an API 6A flange and microstructural analyses and mechanical tests were undertaken to investigate the se…

A description is presented of the friction stir welding (FSW) machine developed for fabrication of the external fuel tanks for the Space Shuttle. The cylindrical part of the tanks was composed of curved panels welded into barrels with welds of const…

Friction stir welding was employed to fabricate dissimilar joints between 5A06-H112 aluminium alloy (Al, 5.8-6.8%Mg, 0.5-0.8%Mn) and 304L stainless steel (0.03%C, 18-20%Cr, 8-11%Ni) and material flow behaviour was investigated by microstructure obse…

Al, 50%Si alloys were joined by friction stir welding (FSW) on spray deposited sheets (thickness 1.5 mm) for butt welding and powder metallurgy plates (thickness 10 mm) for surface welding and the welded joint surface quality and microstructure were…

Optical microscopy, SEM and electron backscattering diffraction techniques were employed to investigate the microstructural evolution and solid-state phase transformations during friction stir spot welding (FSSW: also known as friction spot joining)…

Liquid hydrogen (LH2) produced from renewable energy sources is now recognised as the most promising source of energy to achieve zero carbon emission travel. Thin walled aluminium vessels, lining carbon fibre reinforced polymer (CFRP), could offer a…

Some numerical and experimental results are presented to illustrate the ability of the SignaStir laser ultrasonic testing system to monitor the occurrence of voids, cavities and lack of root penetration defects during friction stir welding (FSW). A …

A simplified finite element modelling approach was employed to analyse the effect of localised dynamic cooling on residual stress development during friction stir welding (FSW), and the model predictions were compared with x-ray synchrotron and neut…

An investigation incorporating experimental measurements and thermomechanical simulations was undertaken to examine the effects of underwater friction stir welding (FSW) on an AISI 321 stainless steel sheet (thickness 3 mm) and to analyse the mechan…

With regard to heavy vehicle component applications, friction stir welding (FSW) and refill friction stir spot welding were employed to fabricate 5083 aluminium multisheet packs for superplastic forming (SPF) into 3D structural or integrally stiffen…

A Lagrangian particle model based on the SPH (smooth particle hydrodynamics) method was developed for friction stir welding (FSW) of similar and dissimilar materials by disregarding elastic deformation and describing plastic deformation by the Johns…

Curved overlap joints of a 7B04 aluminium alloy were fabricated using the "RoboStir" robotic friction stir welding system and their microstructure and mechanical properties were investigated. The experimental set-up incorporated an ABB IRB7600 robot…

The Skew-Stir™ variant of friction stir welding (FSW), in which the axis of the tool is at an angle to that of the machine spindle, is described. The technique provides an improved path for metal to flow around the tool during welding, resulti…

Al, 50%Si alloys were joined by friction stir welding (FSW) on spray deposited sheets (thickness 1.5 mm) for butt welding and powder metallurgy plates (thickness 10 mm) for surface welding and the welded joint surface quality and microstructure were…

Friction stir spot welding (FSSW) experiments were conducted between AA 5052 aluminium alloy and an SP-270C low carbon steel under various process conditions (tool rotation speed 1000-5000 rpm, plunge depth 0.1-0.7 mm), and the microstructure and me…

With regard to the development of additive friction stir deposition (or MELD) as an additive manufacturing process, a mesh-free coupled thermomechanical approach was employed to model MELD by invoking smoothed particle hydrodynamics to discretise th…

Synchrotron x-ray diffraction measurements were used to obtain residual stress state data for welded joints made by friction stir welding (FSW) in AA-5083-H321 aluminium alloys as a function of process parameters (rotational speed and feed rate). Bu…

An investigation is presented into the fatigue properties of welded joints in various structural aluminium alloys prepared by friction stir welding (FSW) and the results are compared with those measured on MIG welded joints. The experimental specime…

Stress corrosion cracking in friction stir welded aluminium alloy joints was investigated using two alternative techniques. Aluminium alloy 7050-T7541 (Al, 5.7-6.7%Zn, 2.0-2.6%Cu, 1.9-2.6%Mg, 0.15%Fe, 0.12%Si) plate of 6.35 mm (0.25 in) thickness wa…