TWI Digital Library

An investigation was undertaken to determine the strength and fracture toughness of joints fabricated by friction stir welding (FSW) in commercial X65 (0.07%C, 1.56%Mn, 0.06%Nb, 0.013%Ti) and X80 (0.05%C, 1.52%Mn, 0.26%Cr, 0.26%Cu, 0.1%Nb and 0.07%C…

Local stress-strain curves were determined from an array of spherical indents on the cross-section of the joint of a friction stir welded (FSW) high strength aluminium alloy AA 2198 sheet, in order to characterise the mechanical properties of differ…

An algorithm and procedure for controlling process zone temperature during friction stir processing are presented. The approach is based on the correlation between weld zone temperature with spindle power. A simplified thermal balance model of the w…

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…

A fully coupled thermomechanical three dimensional finite element (FE) model was developed to analyse the thermomechanical conditions, including material flow and heat generation, at the tool/matrix interface in friction stir welding. The model was …

As part of a study investigating friction stir welding (FSW) as a method for joining the lids on copper canisters for the long term storage of nuclear waste, finite element modelling was used to analyse heat flow and material flow and the developmen…

The effects of tool shoulder size and tilt angle on the formation of weld zones during the friction stir welding of aluminium alloys were studied. Aluminium alloy 5083 (Al, 4.2%Mg, 0.2%Si, 0.6%Mn, 0.15%Fe, 0.09%Cr, 0.09%Zn, 0.06%Cu, 0.02%Ti), an all…

The microstructure and mechanical properties (hardness profiles, tensile strength) of friction stir welded (FSW) joints of ZL114A cast aluminium alloy (Al, 6.5-7.5%Si, 0.45-0.6%Mg), a material of interest for applications in the aerospace industry, …

Friction stir welding (FSW) was applied to the magnesium alloy AZ91 (Mg, 8.21%Al, 0.64%Zn), optimum welding parameters were derived, structural and mechanical properties of the weld zone were determined, and the influence of microstructure on weld p…

The use of friction stir welding to produce aluminium alloy tailor welded blanks for automotive applications was investigated by measuring the hardness and microstructure of friction stir welds in aluminium alloy 5052 (Al, 2.46%Mg, 0.24%Fe, 0.15%Cr,…

Torsion testing was carried out using a range of temperatures and strains to simulate the formation of nugget zone grain structures in friction stir welds of a typical aluminium alloy (7010) in order to investigate the formation mechanisms. Electron…

The effects of pre and post weld heat treatments on the strength, fracture toughness and fatigue crack propagation of welds made by friction stir welding (FSW) in aluminium alloy 6013-T6 sheet material, which may replace the 2024-T3 skin alloy for f…

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…

A stop-action technique was used to stop tool motion during friction stir welding of aluminium alloys in order to study the interactions between the parent material and welding tool pin in the keyhole. Welds were made in 25 mm thick Al-Cu-Li 2195 pl…

Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process dev…

Variations in microstructure in friction stir welds in AA 7449 (Al, 2.2%Mg, 8.2%Zn, 1.7%Cu, 0.12%Si, 0.15%Fe, 0.2%Mn, 0.05%Cr, 0.25 T plus Zr) in the initially overaged (T7) condition were studied. Isothermal heat treatments were conducted at 350 an…

This paper describes the joining criterion for lap joining of dissimilar metal materials of aluminum and stainless steel by friction stir. A criterion for evaluating the joined state or non-joined state is proposed, which is led by the concept based…

Experimental measurements and thermal modelling were used to determine the transient heat loss into friction stir welding tools and so calculate the welding efficiency. Energy inputs were determined from force and torque measurements made whilst per…

Experimental methods were developed to track material flow and mixing during the friction stir welding (FSW) process. Experiments were conducted with butt joints of 6.35 mm (0.25 in) thickness 7050-T7451 aluminium alloy plates. The FSW tool was H13 …

Alternative friction stir welding tool shoulder materials to improve welding speed and quality were evaluated. The materials, which were compared with tool steel using a tool designed for exchangeable shoulder inserts, were: nitrided tool steel, Inc…