TWI Digital Library

Results are presented from tests carried out to determine the mechanical and corrosion properties of friction stir welds in sheets of thickness 4 mm of two aerospace aluminium alloys AA-6056 and AA-6013. The specimens included alloys in the T6 condi…

Lap joints were fabricated in AA 7075-T6 aluminium alloy sheets (thickness 2 mm) using an ESAB "Rosio" friction stir welding (FSW) robot and the effect tool of side-tilt angle on welded joint tensile strength was investigated. A "CounterStir" FSW to…

Friction stir welding developments, equipment, and applications for the joining of aluminium alloys, particularly for automotive applications, are reviewed. Body in white automotive applications include aluminium alloy tailor welded blanks and the m…

A refill friction stir spot welding (RFSSW) process with a short welding cycle time was employed to fabricate welded joints in thin gauge AA 6111-T4 aluminium alloy sheets (thickness 0.9 mm) and the mechanical properties of the joints were investiga…

An investigation is presented into tool material development of large polycrystalline cubic BN blanks to facilitate friction stir welding of thick section steel specimens (thickness 9.5 or 20 mm). Tool materials were produced from 90% polycrystallin…

The deformation behaviour and microstructural evolution of friction stir processed Zn, 22%Al rolled sheet (thickness 3 mm) were compared with those of the corresponding superplastic alloy. Friction stir processing was performed at a rotational speed…

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…

6061-T6 aluminium alloy (Al, 0.96%Mg, 0.59%Si) sheets (thickness 1 mm) were joined by friction stir spot welding (FSSW) under low rotational speed conditions and the microstructure and mechanical properties of the welded joints were investigated. FS…

Dissimilar welded joints between AW 6061-T6 aluminium alloy (Al, 0.93%Mg, 0.59%Si, 0.5%Fe) and AZ31B-H24 magnesium alloy (Mg, 2.55%Al, 0.79%Zn) were fabricated by friction stir welding and the influence of process parameters on their microstructure …

An investigation is presented into the effect of a paint bake cycle on the performance of friction stir spot welded (FSSW) joints fabricated in heat-treatable 6111-T4 aluminium alloy automotive sheets (thickness 0.93 mm) using a pinless tool and sho…

Following a description of the swept FSW spot welding process, experimental work on welding conditions is presented. A design of experiments (DOE) approach was employed to examine the effect of process parameters on unguided lap shear tensile streng…

An apparatus was developed to analyse the contact condition between the rotating tool and the workpiece during friction stir welding, and empirical tests were performed to determine the friction conditions (static, dynamic and the transition from on…

An experimental study was carried out to characterise the types of defect which may occur in friction stir welding (FSW) when operating outside the standard processing window and to determine the causes of these defects. Friction stir welds were mad…

The Welding of Airframes by Friction Stir (WAFS) project was implemented to increase the adoption of friction stir welding (FSW) for welding airframes in the aerospace industry. The partners in WAFS include all the main airframe manufacturers in Eur…

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…

An ultrasound assisted friction stir welding (UA-FSW) technique was employed to fabricate butt joints in similar Al/Al and dissimilar Al/Mg sheets, and the influence of ultrasonic oscillations on weld zone microstructure and mechanical properties wa…

The use of friction stir welding, as an alternative to bolted or riveted joints, for the assembly of Airbus wings is discussed. Issues considered include: cost reduction, weight reduction, joint quality, and enhanced in-service performance. Potentia…

The mechanical properties and microstructures of friction stir butt welds in 6.4 mm and 12.7 mm thickness quenched and tempered martensitic steel plate were compared with those of GMA butt welds in the same parent metal. The friction stir welds in t…

With regard to inconsistencies in the literature concerning the correlation between friction stir welding (FSW) process inputs and post weld process or material response, an investigation is presented into the primary variables (temperature, cooling…

SiC particle reinforced 2124Al metal matrix composite (MMC) plates (thickness 8 mm) were joined by friction stir welding (FSW) and the relationship between process parameters, weld defect formation and joint mechanical properties was investigated. T…