TWI Digital Library

Friction stir welding was employed to fabricate welded joints in Ni-free 18%Cr, 2%Mo, 0.85%N austenitic steel sheets (thickness 3 mm) and the gradient characteristics of the microstructures and mechanical properties were investigated along transvers…

The concept and theoretical principles of friction flow welding are presented. Numerical simulation using 'Deform-3D' software was used to compared and optimise the process. The applicability of friction flow welding to different aluminium alloys wa…

In relation to the industrialisation of the friction stir welding process to facilitate qualification of welding machines for different applications, a methodology is presented based on the interactions between tool, workpiece and material. Issues d…

A report is presented into the "RoboFSW" project, intended to qualify a high payload articulated arm robot for friction stir welding (FSW); hardware modification and control system integration are described and 3D FSW capability is reported for circ…

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…

Two abutting plates (thickness 6 mm) of Al 6061-T6 and cold rolled AISI 1018 mild steel were friction stir welded along the butt joint with the steel and aluminium, respectively, on advancing and retreating sides, and the relationship between proces…

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…

The surface quality, microstructure and crystallographic texture were investigated as a function of traverse speed for friction stir welds of Ti-6Al-4V, produced using static shoulder tools consisting of a tungsten-rhenium probe and a silicon nitrid…

The non-destructive testing (NDT) aspects of the Qualistir project for the on-line quality control of friction stir welding in aluminium are described. Definitions are given for the following defects: voids, wormholes, lack of penetration, faying su…

The development of three-dimensional column-type friction stir welding (FSW) equipment for robotic FSW of joints with complex shapes is described. The process requires a large force and precision control for tool penetration. The specification of th…

An investigation was undertaken into the development and wear performance of friction stir welding (FSW) tools made from precipitation strengthened Ir-containing nickel-based superalloys (Ni, 25%Ir, 14%W, 4%Al) during FSW of Ti, 6%Al, 4%V alloys. Th…

A report is presented into the challenges faced when developing thermal, thermomechanical and flow models of the friction stir welding process, such as the evolution of predictive models, a method to find the correct contact state variable, and the …

A control concept for friction stir welding (FSW) of structural steels was developed based on a closed loop architecture that limits the heat input during the welding process according to the continuously monitored value of the magnetic permeability…

The effects of stir rod angle (0-3 degrees), rotation speed (500-2500 rpm) and travel speed (1-8 mm/s) on metal flow in friction stir welds in pure aluminium (A-1100) and an Al-0.5%Mg alloy (A-5005) were studied. The microstructure, hardness and ten…

The development of robots, tools and control systems for three-dimensional friction stir welding of aluminium alloy plate up to 10 mm thickness is described. Robots have been developed with a triangulated arm construction, which provides the necessa…

Shipbuilding applications of friction stir welding in the production of prefabricated aluminium alloy sections are described. Panels of up to 13 x 16 m, thickness 3-7 mm, may be produced with close tolerances and good surface finish, reducing cost a…

The origin of the lines of micrometre sized oxide particles observed in aluminium alloy friction stir welds was investigated. Butt and bead on plate welds were prepared using 6 mm plate of aluminium (99.999%Al and 99.5%Al) and aluminium alloy 6056 (…

Preliminary results from a 3-dimensional heat and material flow computer simulation program for friction stir welding are given and compared with experimental observations. The simulation is based upon solutions of Navier-Stokes equations and nonlin…