TWI Digital Library

Artificial intelligence (Al) and machine learning (ML) are major drivers for improving quality of manufacturing process including Friction Stir welding. The specific parameter that has 100% effect on the quality of FSW has not yet been identified, h…

Friction stir welds in S355 carbon manganese steel plate of 12 mm thickness were characterised by microstructural studies and measurements of mechanical properties. A tungsten-rhenium alloy tool with a pin length of 7.5 mm was used, running at 400 r…

Friction stir welding was evaluated as a cheaper alternative to the use of fasteners for the joining of lap joints of the aluminium alloy 7075-T351 motor thrust frame of the Ariane 5 rocket. In initial trials to optimise the tool design for lap join…

The use of phased array ultrasonics for the detection of small defects in welds is described, and illustrated using a series of examples of friction stir welded aluminium alloy plate. Phased arrays use an array of ultrasonic elements pulsed with dif…

A discussion is presented on research being undertaken to evaluate friction stir welding (FSW) as a suitable method for joining Airbus aircraft wing structures made of 2000 and 7000 series aluminium alloys. Suitable FSW machines were developed and v…

An investigation was undertaken to explore the feasibility of welding baseline aerospace aluminium alloys along with additional constituents, such as coatings and a faying surface sealant, by the refill friction stir spot welding (RFSSW) technique a…

Spot welds were fabricated in DC01 mild steel and HC 420-LA high strength steel sheets (thickness 1 mm) by friction stir spot welding (FSSW) using various pinless tools and process parameters, and thermographic analysis together with microstructural…

The material point method based on NairnMPM software was employed to formulate a 2D model of elastoplastic material flow around a friction stir welding (FSW) tool probe and to examine 2D elastoplastic deformation and the frictional interaction at th…

3rd International Symposium, 27-28 Sep 2001, Poster Session, Paper 13

A series of friction stir welding (FSW) experiments using threaded tool pins and AA5083 (Al, 4.5%Mg, 0.6%Mn) or A356 (Al, 7%Si, 0.3%Mg) workpiece alloys was undertaken in order to understand material flow mode within thread spaces and its influence …

A production-capable friction stir welding (FSW) process was developed for butt welds (penetration 25.4 mm) in 6061-T6 aluminium alloys, designed specifically for robotic welding of large box assemblies requiring many multi-dimensional weld paths, a…

An accurate temperature feedback strategy and closed-loop feedback control system for temperature have been developed for friction stir welding. A wireless data acquisition system was constructed to measure temperatures at the tool-workpiece interfa…

Friction stir welding trials were undertaken on AA 7075-T7351 aluminium alloy plates (thickness 9.525 mm) to investigate the influence of backing plate characteristics on heat input and cooling rate. Experiments were performed on an MTI RM2 friction…

The large load friction stir spot welding (LL-FSSW) technique was applied to a low carbon steel sheet in order to achieve lap joints at a low temperature, and the microstructure and hardness of the joints were investigated. The composition of the gr…

A device was designed and manufactured to facilitate accurate monitoring of forces, torque and tool temperature during friction stir welding (FSW) and for use as a weld quality indicator in relation to issues such as tool wear, lack of tool penetrat…

The main factors to be considered in the automation and robotisation of friction stir welding (FSW) and the production of one-, two- and three-dimensional welds were identified. A FSW robotic cell was developed and force control algorithms were defi…

A fully Lagrangian smoothed particle hydrodynamics method was employed to simulate the bobbin tool friction stir welding process for aluminium alloys in order to evaluate tool torque and forces as well as material flow for different advancing speeds…

Numerical modelling and experimental measurements were undertaken to investigate the heat flux and residual stresses during a rotary friction welding process to fabricate joints between an ASTM A36 steel pipe (0.11%C, 0.2%Si, 0.92%Mn, 0.02%Cr, 0.02%…

The stationary shoulder friction stir welding (SSFSW) process was employed to fabricate defect-free joints in a variety of aluminium alloys and experiments were undertaken to investigate the microstructure and mechanical properties of the joints. Th…

Following a summary of the current applications for friction stir welding at Boeing, the Brotje Automation FSW system is introduced. Presentation slides give notes on complex contour FSW in a large work envelope, the characteristics of a robust prod…