TWI Digital Library

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.…

Two techniques developed on TWI's "RoboStir" system, robotic floating-bobbin friction stir welding (RFBFSW) and robotic stationary shoulder friction stir welding (RSSFSW), are described and some results from welding trials are presented. The RFBFSW …

A friction melt bonding process was employed to fabricate dissimilar lap joints between ultralow carbon (0.01%C, 0.14%Mn) or dual-phase DP600 (0.08%C, 1.51%Mn, 0.35%Cr, 0.06%Mo) steel grades and 1050, 2024 or 6061 aluminium alloys and the microstruc…

The stationary shoulder technique was applied to the self reacting pin tool (SRPT) for friction stir welding (FSW) of high quality aluminium alloy railway car body structures in order to enhance the appearance of no coating side structures construct…

Controlled force monitored plug-in tests were undertaken to investigate the influence of rotational speed and to analyse flow regimes during friction stir welding (FSW) of different aluminium alloys. Experimental specimens comprised sheets (thicknes…

A thermal model with a thermo pseudo mechanical (TPM) heat source was employed to investigate the influence of process parameters (rotational speed, feed rate and tool geometry) on the temperature profile at the interface of dissimilar metal lap joi…

AA 2219 aluminium alloy sheets (thickness 2.5 mm) were joined by friction stir welding (FSW) and an investigation was undertaken into the relationship between joint mechanical properties, the torque generated by the spindle motor and process variabl…

A kinematic approach is presented for modelling the friction stir welding process and the relationship between tool geometry and process parameters. The model was used to describe the correlation between features of the weld nugget, process paramete…

Vertical and angular truss extrusions made from 6082-T6 aluminium alloy (Al, 0.7-0.74%Mg, 1.04-1.14%Si, 0.53-0.54%Mn) were friction stir welded in a half-overlap configuration to fabricate panels for marine applications and their fatigue performance…

A cantilever type rotary bending fatigue testing machine with high speed loading capability was employed to investigate the high cycle fatigue properties of the stir zone, thermomechanically affected zone and HAZ in friction stir welded joints of va…

Friction stir welding experiments were conducted on AA 2024-T3 Al-Cu-Mg alloys to investigate the influence of backplate design on joint microstructure and mechanical properties. Trials were performed using three specially designed backplates based …

Periodic material phenomena around a threaded pin in friction stir welding (FSW) were investigated with a fully transient thermomechanically coupled numerical simulation, in which the transient motion of the threaded pin was included in the computat…

A plastic replication technique was employed to investigate surface crack initiation and growth in 2024-T351 Al alloy friction stir welded (FSW) joints during fatigue bending tests. Fatigue failure mechanisms were examined, and a modified Hobson-Bro…