TWI Digital Library

A 3D fully coupled computational fluid dynamics model was established to investigate the heat generation and material flow during friction stir welding, and the measured tool torque and axial force were used to characterise the contact conditions (f…

Friction stir welding (FSW) was carried out on AZ31 magnesium alloy (Mg, 3%Al, 1%Zn) plates of thickness 6 mm in order to examine the relationship between weld microtexture and tensile properties. Orientation imaging microscopy was used to examine m…

The origin of the lines of micrometre sized oxide particles observed in aluminium alloy friction stir welds was investigated. Butt and bead on plate welds were prepared using 6 mm plate of aluminium (99.999%Al and 99.5%Al) and aluminium alloy 6056 (…

Thermomechanical and microstructural modelling were performed for the friction stir welding process, simulating the thermal diffusion during and after welding (in the cooling stage), and comparing the results with experimental data obtained for fric…

The design of a polycrystalline cubic boron nitride friction stir welding tool, tool holder and machine for use with high melting temperature materials is described. A polycrystalline cubic boron nitride truncated cone tool tip, capable of working a…

The use of friction stir welding for the repair of cracks in aluminium alloy 2024 aircraft wing skin structures, and the repair fatigue life were investigated. An artificial crack, 42 mm in length, in a flat section 2024-T351 alloy of 3.2 mm thickne…

A friction stir spot welding process was employed to fabricate dissimilar joints between 6016 aluminium alloy (Al, 1-1.5%Si, 0.25-0.6%Mg) and galvanised HSLA 280 phosphorus-hardened cold rolled steel (0.08%C, 1.3%Mn, 0.1%Ti, 0.08%Al, 0.09%P), and th…

An accurate temperature feedback strategy and closed-loop feedback control system for temperature have been developed for friction stir welding. A wireless data acquisition system was constructed to measure temperatures at the tool-workpiece interfa…

The swept frequency friction stir spot welding technique was employed to fabricate lap joints in 6061 aluminium alloy workpieces and the influence of process parameters on mechanical properties was investigated. Welding experiments were conducted us…

Incorporation of friction stir welding (FSW) in a parallel kinematics machine (PKM) 5-axis machine was undertaken with the intelligent computer aided manufacturing (ICAM) approach to optimise process parameters and tool paths by using available CNC …

Friction stir welding (FSW) experiments were undertaken on single crystal and polycrystalline pure iron sheets (thickness 1.5 mm) as well as a polycrystalline carbon steel, and the microstructure, material flow characteristics and plastic deformatio…

A man-machine interface for friction stir welding (FSW) was proposed that allows a human operator to augment a traditional control system by monitoring and continuously adjusting the parameters of an established welding programme, and hardware and s…

Friction stir processing (FSP) experiments were undertaken on annealed AISI 420 stainless steel plates (thickness 6 mm) in order to compare three methods for assessing tool wear. The investigations incorporated two tool compositions (WC-Co or polycr…

The degradation mechanisms of friction stir welding (FSW) tools made of three tungsten alloys were investigated. Tools were made from 99%W-1%La2O3, 75%W-25%Re and 70%W-20%Re-10%HfC. These were used to make friction stir welds in high strength steel …

The hybrid component of the combination magnesium’s lightness and aluminum’s formability should be useful for energy saving. The welding of dissimilar metallic materials is difficult for their difference in melting temperatures and the formation of …

A tool made from a Co-based alloy strengthened by precipitation of an intermetallic Co3(Al,W) gamma phase with an L12 structure was developed for friction stir welding of high-softening-temperature materials, such as a 0.45%C steel, and the tool wea…

Hot rolled AZ31 magnesium alloy plate of 6.3 mm thickness was friction stir welded (FSW) at rotation rates of 600-4000 rpm and a constant welding speed of 100 mm per minute and the microstructure and mechanical properties of the joints were investig…

A new aluminium-bodied, mid-engined AUDI sports car is the first serial application for friction stir welded tailored blanks worldwide. 6th International Symposium, 10-13 Oct 2006, Session 9B: Modelling II, Paper 03

Dissimilar joints between AA 6060-T5 aluminium alloy plates (thickness 6 mm) and Ti-6Al-4V titanium alloy sheets (thickness 2.5 mm) were fabricated by friction stir lap welding (FSLW) and the influence of interface microstructures on the value of ma…

The microstructure, crystallographic texture and grain distribution were determined in a transverse cross section of a friction stir weld and in a plan-view section through the embedded friction stir welding (FSW) tool. The weld was obtained by FSW …