TWI Digital Library

An economic analysis was undertaken to compare the costs of onshore and offshore pipeline construction scenarios for welds made using friction stir welding (FSW) and conventional mechanised MIG/MAG welding. Pipe diameters of 1067 and 305 mm were sel…

A hybrid welding system called ultrasound supported friction stir welding was developed to mitigate the strength reducing effects of brittle intermetallic phase layers and was applied to the fabrication of dissimilar joints between wrought aluminium…

Models to predict the precipitate and grain size evolution in AA7449 aluminium alloy friction stir welds are presented and compared with experimental data. Bead on plate welds on 3.2 mm thickness sheets of composition Al, 8.4%Zn, 2.1%Mg, 1.8%Cu were…

A comparative study was undertaken of three different machine types, a modified high payload robot, a CNC milling machine and an ESAB "SuperStir" FSW machine, in terms of their capability for FSW of various aluminium alloys using identical process p…

An experimental investigation was undertaken to examine how tool pin induced material flow and intermetallic growth conditions affect the formation of discontinuity during friction stir lap welding of dissimilar Al-Cu joints. The materials comprised…

A two-step modelling procedure, consisting of a thermo-fluid model and a thermo-mechanical model, was employed to predict temperature, flow and residual stress fields around the workpiece block, steel backing plate and tool in friction stir welding …

A thermal-pseudo-mechanical model, based on the use of material temperature-dependent yield stress as the driver for heat input, was proposed for heat generation in friction stir welding, and simulation results were compared with experimental temper…

Butt joints were fabricated in sheet specimens of 2017A-T451 alloys (Al, 4.14%Cu) and cast plates of Al, 8.6%Si, 0.31%Mg by friction stir welding (FSW) and their microstructure and mechanical properties were investigated. Welding experiments were co…

Friction stir welding experiments were undertaken on 2195-T8 (Al, 3.99%Cu, 1.09%Li) alloy sheets (thickness 5 mm) and the weldability, microstructure and mechanical properties of the fabricated butt joints were investigated. Welding was performed us…

The application of suitable friction stir welding (FSW) tools and procedures to common structural geometries in industry, with emphasis of FSW of hard metals including steel, titanium and nickel based alloys in butt, T-joint, corner joint and circum…

A controller was developed and tested for the friction stir welding of copper canisters, used in the nuclear industry. The cascaded loop controller determines the power input requirement and tool temperature to achieve a stable, robust and repeatabl…

A friction stir welding tool with a variable length probe (suitable for variable thickness joints, repairs and circumferential welding) was developed and evaluated for the welding of aluminium alloy 2195. Tapered sheet, of both increasing and decrea…

Dissimilar lap joints between aluminium alloys and various steel grades were fabricated by friction stir welding (FSW), FSW tool wear was measured and a phenomenological law was developed with respect to pin length reduction over weld length to repr…

A review is presented of the progressive emergence of conceptual tools associated with friction stir welding (FSW) at the Marshall Space Flight Center, USA, from the discovery of the shear surface, wiping metal transfer and the invention of a kinema…

With regard to the development of the stationary shoulder friction stir welding (FSW) technique as a long term loading joining process offering enhanced weld seam mechanical properties, an investigation is presented into coordinated material flow be…

Based on lessons learned from the MegaStir research programme devoted to friction stir welding (FSW) of high temperature alloys and with the aim of producing high quality, defect free welded joints while maximising tool life, a report is presented i…

A friction stir welding (FSW) procedure, incorporating the use of different tool pins in combination with concave or scroll type shoulders, was employed to join various aluminium alloys; material flow was investigated with the aid of computer micro-…

Neutron and synchrotron x-ray diffraction techniques were employed to determine the effect of global mechanical tensioning on residual stress in friction stir welded joints fabricated in AA 2199-T8 (Al, 2.63%Cu, 1.56%Li) and AA 7449-W51 (Al, 7.5-8.7…

Dissimilar lap joints were fabricated between 6022 aluminium alloy and SPCC low carbon steel using friction stir welding (FSW) and the effect of probe tip position on microstructure and mechanical properties was investigated. FSW was performed at a …

Friction stir welding (FSW) is a solid-state joining method, being well-known to be suitable particularly in joining of aluminum in all alloy and manufacturing forms. The technological advantages of FSW can be also expanded to high-strength steel ma…