TWI

Dissimilar lap joints between AlSi10MgMn aluminium alloy sheets (thickness 3 mm) and Al-Si coated Usibor 1500 22MnB5 hot stamped boron steel sheets (thickness 1.8 mm) were fabricated by friction stir spot welding (FSSW) under different processing co…

A review is presented of process development work undertaken with regard to a machine concept assessment and the realisation of a fully 3D-capable 5-axis parallel kinematic friction stir welding machine, a so-called pentapod, suitable for large and …

Butt welding experiments were undertaken to investigate the feasibility of joining a metal matrix composite (MMC), comprising an Al-10%Si matrix and 20 vol.% SiC particles, to an AA-6063-T5 alloy by friction stir welding (FSW). Optimum process param…

An experimental investigation is presented into the precipitation and hardening mechanism during FSW (friction stir welding) of Ni model alloys (Ni, 20%Cr, 2%Al, 2%Ti and Ni, 20%Cr, 3%Al, 3%Ti) in which Al and Ti contents were varied to control the …

Friction stir spot welding experiments were conducted on dissimilar metal joints between AA5052 aluminium alloy and three kinds of zinc coated steel, and weldability analysis, microstructure observations and mechanical tests were undertaken. The coa…

Friction stir processing (FSP) experiments were undertaken to modify the microstructure of Ti-6%Al-4%V parent metal specimens, in both alpha/beta and beta processed conditions, and TIG weld overlays deposited onto Ti, 6%Al, 4%V alloy using matching …

A 3D thermomechanical model, incorporating knowledge of residual distortion and stress, was developed as a finite element tool for simulation and optimisation of clamping situations in friction stir welding (FSW) and experiments were undertaken on A…

Similar and dissimilar joints between 2014-T6 (Al, 4.67%Cu) and 6061-T6 (Al, 0.9%Mg, 0.63%Si) aluminium alloys were fabricated by friction stir welding (FSW) with various sets of process parameters, and the microstructure and mechanical properties o…

An investigation is presented into the influence of friction stir welding (FSW) process parameters (tool rotation speed and feed rate) on the mechanical properties and microstructure of welded joints of AA2095 (Al, 4.6%Cu, 1.14%Li) in as-welded and …

A description is presented of the process flow of a production job based on friction stir welding (FSW) for the serial production of aluminium drying trays for the food industry. FSW joint quality issues (joint impermeability, weld surface quality a…

Technology improvements and process innovations in respect of friction stir welding (FSW) of high temperature materials are reviewed, welding process conditions and mechanical properties of completed welds for various alloys using polycrystalline cu…

An experimental study was carried out to investigate friction stir welded lap joints in AA-6082 aluminium alloy sheets in order to determine methods to improve weld quality; the experiments were performed using two different types of probe, the MX-T…

The use of friction stir processing (FSP), a process derived from friction stir welding, to tailor a material's microstructure locally to achieve maximum performance was investigated. Superplastic behaviour was examined in friction stir processed 5 …

The mechanical properties and microstructures of dissimilar butt welds made between aluminium die casting alloy ADC1 (Al, 11.9%Si, 0.37%Fe, 0.44%Mg) and the extruded alloy A-6061-T6 (Al, 0.84%Mg, 0.67%Si) were studied. The materials were 4 mm thick …

An experimental study was carried out to investigate the effect of welding conditions on weld macrostructure and the microstructure and mechanical properties of the nugget zone in welds in AA-7010 aluminium alloy made by friction stir welding (FSW).…

The surface and near-surface residual stress distributions of friction stir welds in three different aluminium alloys were measured using an x-ray diffraction technique. Welds in very low alkali and hydrogen content Al-Li alloy C458 (Al, 1.73%Li, 2.…

Friction stir butt welds of Al alloy (2024, 6013 and 6056) sheets (4 mm thickness) were examined by conventional ultrasonic inspection with a single focused transducer (25 MHz frequency), facilitating the detection of void-like flaws as well as the …

A description is presented of the friction stir welding (FSW) machine developed for fabrication of the external fuel tanks for the Space Shuttle. The cylindrical part of the tanks was composed of curved panels welded into barrels with welds of const…

Friction stir welds were made in the austenitic stainless steels 304L (thickness 6.4 mm (0.25 in) and 3.2 mm (0.125 in)) and the superaustenitic stainless steel AL 6XN. Welds in the 3.2 mm sheet were made in a single pass. The 6.4 mm plates were wel…

The production of aluminium alloy forged suspension parts for light-weight vehicles using circumferential friction stir welding (FSW) is considered. The suspension arm is composed of three extruded shapes (bush bracket, yoke and pipe) joined by FSW.…