TWI Digital Library

Lap joints were fabricated in 2024-T3 aluminium alloy sheets (thickness 1 or 0.6 mm) by refill friction stir spot welding (RFSSW) and the influence of tool sleeve depth on joint quality was investigated. Welding was performed at tool depths of 1.1-1…

Butt joints were fabricated in AA 6061-T6511 aluminium alloys by friction stir welding (FSW) and the influence of the welding equipment rigidity on their microstructure and mechanical properties was investigated. The experimental set-up incorporated…

Butt joints were fabricated in a Ruuki Optim 700 MC Plus microalloyed low carbon high strength complex phase steel (0.06%C, 1.79%Mn, 0.01%V, 0.08%Nb, 0.11%Ti) using one-sided and two-sided friction stir welding in order to investigate the difference…

Friction stir processing (FSP) was employed to repair casting defects such as shrinkage cavities and porosity in nickel aluminium bronze, and the corrosion behaviour of the processed material was examined through short-term and long-term testing and…

The microstructural evolution during FSW of beta-annealed plates of Ti-5111 (Ti, 5%Al, 1%Sn, 1%Zr, 1%V, 8%Mo) was investigated above and below the beta transus temperature. Variable penetration tools of a refractory-based material with different dim…

Low temperature friction stir welding (FSW) was employed to join three types of carbon steels and the effects of carbon content, process conditions and phase transformations on the microstructure and mechanical properties of the welded joints were i…

To study the feasibility of SFW (spot stir friction welding) with adhesive, a process that is also called spot friction weld-bonding, aluminium 6111-T4 coupons (25x100 mm, thickness 0.9 and 1.0 mm) were used to produce SFW specimens in a lap shear c…

A phenomenologically based semiphysical modelling approach was employed to develop a process window for friction stir welding (FSW) of AA 2024-T3 aluminium alloy, incorporating simulation of the filling level of the welded joint as a means to determ…

A numerical simulation is presented for the development and integration of a pin tool for friction stir welding (FSW) of aluminium alloys. The Triflute tool design was optimised. The macro- and microstructure of lap joints in A6N01 alloys were studi…

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…

Thermodynamic modelling and experimental measurements were employed to investigate the influence of intermetallic compound formation on the shear strength of dissimilar joints between an aluminium alloy and ultra-high strength steel fabricated by fr…

A 3D fully coupled computational fluid dynamics model was established to investigate the heat generation and material flow during friction stir welding, and the measured tool torque and axial force were used to characterise the contact conditions (f…

Dissimilar lap joints between ASTM A36 low carbon steel and Inconel 625 (Ni, 21.4%Cr, 9.65%Mo, 3.2%Nb, 2.6%Fe) were fabricated by friction stir welding (FSW) and the effects of process parameters on microstructure and hardness were investigated. FSW…

A qualitative and discrete quantitative approach was adopted to develop a generalised electronic NDE (e-NDE) algorithm for identifying erratic friction stir welding (FSW) indications contained in the tool force feedback signals as low and high frequ…

With regard to the dependence of welded joint properties on tool probe shape during friction stir welding (FSW) of dissimilar butt joints between aluminium and steel, an investigation was undertaken into the interface formation mechanism by conducti…

A simplified friction stir welding (FSW) tool equipped with an adjustable probe was developed, FSW trial results with prototype tools were obtained and were analysed in terms of weldability. The simplified tools were realised by devising shoulders f…

A high rotational speed friction stir welding (FSW) procedure based on the use of a fixed shoulder tool was developed to facilitate the production of strong metallurgical joints at comparatively low process forces, and microstructural observations a…

To understand the influence of dwell time in friction stir welding (FSW) and thus to optimise its value, spot welds were produced between superposed sheets of 6008 aluminium alloy and industrial steel (thickness 2.5 and 2 mm, respectively), and thei…