TWI Digital Library

The joining of hot rolled aerospace quality AZ31B-H24 magnesium alloy (Mg, 2.5-3.5%Al, 0.7-1.3%Zn, 0.2-1.0%Mn) sheets (thickness 4.95 mm) was investigated using an MTS ISTIR friction stir welding (FSW) machine, the quality of the butt joints produce…

An overview is presented of the twenty year history and technological developments relating to the application of friction stir welding (FSW) to aluminium alloy railway car body shells. Issues discussed include the history of railway car body shell …

An investigation is presented into a methodology for simulating the entire friction stir welding (FSW) process using a hybrid mesh free method on a graphics processing unit (GPU) and its implementation for different FSW applications such as butt joi…

Quantification approaches applied to phase space data generated from friction stir welding aluminium alloys under varying process conditions are reported. A multi-step, micro-wormhole, non-destructive evaluation phase-spaced, (PS) algorithm that com…

Numerical simulations and experimental tests were undertaken to visualise material flow and to study the effect of the flow field on the mixing mechanism and particle break-up in friction stir welding of metal matrix composites. A 3D thermo-fluid mo…

A brief review is presented of the state of development of polycrystalline cubic boron nitride (PCBN) tool materials for friction stir welding (FSW) of high-temperature materials (high alloy steels and Ni based alloys) with respect to weld penetrati…

Fatigue tests were performed using lap-shear specimens of friction stir spot welded Al, 0.8%Mg, 1%Si alloys. Sheet specimens (thickness 2 mm) were subjected to PWHT of solution treatment and/or ageing. Weld zone microstructure was observed by SEM. F…

Nondestructive testing of friction stir welds is discussed. The ultrasonic testing of friction stir welded joints, advantages of phased array testing and test applications are presented briefly. The eddy current array testing technique is illustrate…

The feasibility of using friction stir welding (FSW) in the construction of an aircraft central wing box from butt-welded extrusions was evaluated. An FSW procedure for welding 7055 T77511 and 7349 T6511 10 mm thickness extrusions was developed by T…

The design, construction and use of a purpose-built friction stir welding machine for the welding of 15.9 mm (0.625 in) thickness, 1.88 m (74 in) long aluminium alloy 6061-T6 plate and extruded sections to form the side panels of a laser system is d…

A softening model was constructed for friction stir welding (FSW) of 2xxx series aluminium alloys and was combined with previously derived thermal cycle modelling work. A thermal model of energy input and heat conduction was used to calculate therma…

5083-O aluminium alloy sheets (thickness 3 mm) were butt welded using a gate-type friction stir welding (FSW) machine to investigate tolerance to deviations in butt-line/tool-travel line, gap spacing and tool roll angle, and the welded joints were e…

With regard to the development of hybrid friction stir welding-adhesive bonding (FSW-AB) for the fabrication of lap joints, a mesh free coupled thermomechanical simulation of the FSW-AB process was undertaken using the SPHriction-3D code and the num…

The development of friction stir welding (FSW) as a potential low distortion, cost-effective joining method for HSLA-65 steel T-joints is presented with reference to application in the ship building industry. Experiments were carried out on steel (0…

An investigation is presented into the processing window for friction stir welding (FSW) of Formall 545 (equivalent to AA-5083) to age-hardened AA-6082 aluminium alloys with regard to tool rotation and traverse speeds, and into an evaluation of a nu…

Rolled homogeneous armor (RHA) steel is widely utilized in the armor industry due to its cost-effectiveness and outstanding ballistic performance against various battlefield threats. As the industry pursues lightweight solutions and addresses soften…

In relation to the application of tailor welded blanks of aluminium alloys to the vehicle weight reduction process, an investigation is presented into the precipitation sequence in friction stir welded 6016 alloy sheets (thickness 2 mm) during a pai…

The aim of this investigation was to study morphological, mechanical and microstructural properties of similar and dissimilar friction stir welds in 1 mm thick sheets of phosphorous-­deoxidised copper and 5083-H111 aluminium alloy. At the weldin…

Sleeve plunge friction spot welding was employed to join AA5042 aluminium alloys under various process conditions and the microstructure and the mechanical properties of the welded joints were investigated. Welding was performed using a three-piece …

A procedure has been developed for repairing welds made by friction stir welding (FSW) in cases where the tool breaks during welding. It involves the following stages: excavating the broken FSW tool, milling out a slot across the hole, machining an …