TWI Digital Library

With regard to the application of friction stir welding (FSW) for the butt weld joining of aluminium alloy extrusions into large panels for ship decks and railway carriages, an investigation is presented into the employment of laser ultrasonic testi…

Haynes Alloy 282 (Ni, 19.45%Cr, 10.28%Co, 8.55%Mo) was deposited onto Inconel 600 substrates (Ni, 16.69%Cr, 9.36%Fe) using a cold-wire TIG process, subjected to additive friction stir processing (AFSP) to create gamma-strengthened surface layers, an…

The influence of weld length on pin breakage during friction stir welding (FSW) of aluminium alloy was investigated. Tool geometry, microstructure, pin diameter and the occurrence of cracking were studied during welding. Welded joints were made in 7…

A numerical and experimental study was undertaken to investigate the mechanism of swing friction stir spot welding (FSSW) and the effects of swing length and weld direction on the joint strength. Coupons were taken from a commercial A6022-T4 alumini…

Friction stir welding (FSW) using a milling machine was employed to join AA-6063-T6 alloy (Al, 0.51%Mg, 0.42%Si) pipes (diameter 110 mm, thickness 5 mm) with the aim of eliminating ploughing problems, and weld zone microstructures were studied as a …

Dissimilar joints between 6061-T4 aluminium alloy and S45C steel sheets (thickness 1.6 mm and 1 mm, respectively) were fabricated by the friction stir clinching technique using two types of tools and their mechanical properties and failure modes wer…

Friction stir linear welding and friction stir spot welding techniques were employed to fabricate robust and reliable welded joints for automotive front end substructure applications between AA6022-T4 aluminium alloy and AM60B magnesium alloy sheets…

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…

Friction stir welding (FSW) is discussed in manufacture of a sports car body made largely of aluminium alloy sheet with some components of cast aluminium or extruded aluminium, and the only steel used is the frame for the windscreen. Advantages are …

Multirun friction stir processing (FSP) (12 mm depth over large surface area) was performed on NiAl bronze (Cu, 9.1%Al, 4.4%Ni, 3.9%Fe) thick plates (thickness 40 mm) using a rectangular spiral-out raster path, and longitudinal residual stresses wer…

The microstructure and corrosion properties of welded joints in Inconel 22 (Alloy 22 or NO6022) made by friction stir welding (FSW) were investigated. Bead-on-plate welds were produced in Alloy 22 (59.6%Ni, 13.43%Mo, 0.22%Cr, 3.29%W, 3.17%Fe, 0.84%C…

Modified Gleeble hot torsion testing was used to simulate four microstructure regions in HSLA-65 steel (0.07%C, 0.24%Si, 1.5%Mn, 0.14%Cr, 0.34%Ni, 0.25%Cu, 0.06%Mo) joints fabricated by friction stir welding (FSW) and the results were verified by op…

An approach to welded joint inspection incorporating in situ characterisation of weld quality was developed to facilitate the detection of discontinuities (e.g. voids and volume defects) during friction stir welding (FSW). FSW experiments were perfo…

A friction stir welding (FSW) process map for AA 7075-T6 aluminium alloy (Al, 5.1-6.1%Zn, 2.1-2.9%Mg, 1.2-2%Cu) was determined using combined NDT techniques such as visual inspection, dye penetrant testing, X-ray radiography and ultrasonic testing a…

In relation to weight and cost saving on spaceflight pressure vessels, two friction stir lap welding methods were demonstrated on large-scale thin-gauge hardware and evaluated with respect to tooling and tooling cost reduction, lap joint stiffness a…

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…

A methodology to facilitate cost-effective friction stir welding (FSW) of large and complex 3D structures is presented based on a parallel kinematic machine concept called Pentapod, and welding trial results for spherical structures and dissimilar m…

Modelling tools were developed to describe the relationships between process parameters, microstructural evolution and mechanical properties of the weld in friction stir welding (FSW). Experiments were conducted using aluminium alloy 6056. Initial t…

Computational fluid dynamics (CFD) methods were used to model the metal flow in the friction stir welding (FSW) process in order to optimise the pin profile to minimise the traversing force; welding experiments were carried out to validate the findi…

Friction stir welding (FSW) was investigated in aluminium alloys used in aircraft structures. Extruded shapes in alloys 2024 (Al, 4.96%Cu), 7475 (Al, 5.96%Zn, 2.57%Mg, 1.62%Cu) and 7050 (Al, 6.29%Zn, 2.36%Mg, 2.00%Cu) were welded; welds were evaluat…