TWI Digital Library

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…

The ScanStir framework, comprising an experimental friction stir welding (FSW) set-up, numerical models based on open source finite element method software packages, and a high performance computer, was used to simulate the residual stress profile i…

Similar and dissimilar T-joints were made by friction stir welding (FSW) of 3 mm thickness 2024-T3 cover sheet combined with 2.5 mm thick stiffeners consisting of either 2024-T3 or 2098-T8 (stringer) material. During welding the pin penetrated the s…

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…

An experimental investigation was made of the effect of welding tool shape on welding defects and material flow during friction stir welding (FSW) of dissimilar materials. Friction stir welding tools used had tool shoulders of tool steel and the pro…

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…

With regard to the development of the stationary shoulder friction stir welding (FSW) technique as a long term loading joining process offering enhanced weld seam mechanical properties, an investigation is presented into coordinated material flow be…

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…

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…

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…

The mechanical properties of the parent metals and friction stir welded joints in aluminium alloy 6 mm plate 2014A, 7075 and 5083 are summarised. CTOD and J fracture toughness results are reported for the parent metal and up to five different region…

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…

Friction stir spot welding (FSSW) was employed to fabricate lap joints in hot extruded AZ31 magnesium alloy sheets (thickness 2 mm), and the effect of introducing nanostructured SiC particles (mean size 40 nm) on the microstructure and mechanical pr…

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 stationary shoulder friction stir welding (SSFSW) process was employed to fabricate defect-free joints in a variety of aluminium alloys and experiments were undertaken to investigate the microstructure and mechanical properties of the joints. 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…

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…

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)…