TWI Digital Library

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…

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…

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 …

3D fully-coupled thermomechanical models implemented in the ABAQUS finite element code were developed to investigate residual stresses and distortion in friction stir welding (FSW) and three case studies were examined. The temperature field obtained…

Friction stir welding (FSW) experiments were conducted on commercially pure titanium sheet (thickness 3 mm) to identify the optimum tool material and process conditions; the microstructure and mechanical properties of the welded joints were determin…

An experimental study was made of the effect of friction stir processing (FSP) and the influence of process parameters on the microstructure and mechanical properties of cast magnesium AZ91 alloy. FSP tests were conducted on die cast plates of 4 mm …

Dissimilar lap joints were fabricated between 6022 aluminium alloy and SPCC low carbon steel using friction stir welding (FSW) and the effect of probe tip position on microstructure and mechanical properties was investigated. FSW was performed at a …

The electrically assisted friction stir welding (EAFSW) technique, in which an electric current is fed through the workpiece to soften the metal by means of ohmic heating, is described and some trial experimental results are reported. The initial EA…

With regard to the application of wear resistant surface layers on chosen substrates, an investigation is presented into the deposition of cermet (WC, 10%Co, 4%Cr or Cr3C2-NiCr) and oxide (Al2O3) coatings onto AA 5083 aluminium alloy substrates by c…

A review is presented of the development of W, 25%Re friction stir welding (FSW) tool materials for application to steels and hard metals, such as titanium and nickel-based superalloys. Issues discussed include: the DUST (dual use science and techno…

Based on lessons learned from the MegaStir research programme devoted to friction stir welding (FSW) of high temperature alloys and with the aim of producing high quality, defect free welded joints while maximising tool life, a report is presented i…

Friction stir welding (FSW) experiments were conducted on a variety of materials and grain structure development, material flow characteristics and crystallographic texture formation were examined by high-resolution electron backscatter diffraction.…

In this study, the mechanical properties and metallurgical joining interface of aluminum alloy and various strength steel joints by scrubbing refill FSSW (Sc-RFSSW) were investigated. It was shown that Sc-RFSSW provides higher joint strength than co…

Dissimilar lap joints between AA 6061-T6 (Al, 1.01%Mg, 0.59%Si) and A356 (Al, 7.02%Si) aluminium alloys were fabricated by friction stir welding (FSW) and the influence of process conditions on joint microstructure evolution and mechanical propertie…

An investigation was undertaken to examine the interactions, required process adjustments and resultant joint properties associated with conventional and robotic stationary shoulder friction stir welding (SSFSW) for scaled tool geometries. In order …