TWI Digital Library

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…

Friction stir welding (FSW) experiments were undertaken on sheet specimens (thickness 4 mm) of AISI 304 stainless steel (17.5-19.5%Cr, 8-10.5%Ni) using different uncoated and coated tungsten and WC-based tools, and tool wear and failure mechanisms w…

Friction stir welding (FSW) was employed to fabricate a single overlap joint between sheet specimens (thickness 1.5 mm) of an AA 6181-T4 aluminium alloy and ZStE-340 high-strength steel, and weld phase composition, microstructure and mechanical prop…

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…

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…

With regard to the occurrence of coarse alpha-Al dendrites, eutectic phase, shrinkage porosity and other defects in cast aluminium alloys, an investigation was undertaken into the influence of different combinations of friction stir processing (FSP)…

With regard to the development of friction stir shaping as a modified friction stir welding (FSW) process to maximise material flow within the weld zone and redistribute it into new shapes or features outside of or on top of the weld zone, an invest…

In order to study the relationship between material flow and the development of highly variant process forces during friction stir welding (FSW), a high sampling rate triaxial force measurement device and a high speed camera were employed to monitor…

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…

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…

An investigation is presented into the development of the stationary shoulder self-reacting pin tool (SSSRPT) as a friction stir welding variant and the application of the tool to fabrication of butt joints in sheets (thickness 4 mm) of A6N01 alloys…

A friction stir welding technology was developed to facilitate welding extruded profiles together as a whole side wall in an aluminium railway wagon for coal transportation. The material employed was an AA 6061-T6 alloy plate (thickness 7 mm). Some …

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…

Friction stir welding experiments between AA 6063 aluminium alloy and S45C carbon steel (thickness 6 mm) were performed, and the effects of heat input on the butt joint macrostructure (cavities formed at weld interface), hardness and plastic flow of…

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 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 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…