TWI Digital Library

An accurate temperature feedback strategy and closed-loop feedback control system for temperature have been developed for friction stir welding. A wireless data acquisition system was constructed to measure temperatures at the tool-workpiece interfa…

Two common approaches to describe kinematics in simulations of the friction stir welding (FSW) process, the Lagrangian representation and the Eulerian representation, were compared using "ABAQUS/Explicit" and "FLUENT" software programs, and the infl…

A production-capable friction stir welding (FSW) process was developed for butt welds (penetration 25.4 mm) in 6061-T6 aluminium alloys, designed specifically for robotic welding of large box assemblies requiring many multi-dimensional weld paths, a…

Friction stir welding (FSW) of 2219-T6 aluminium alloys (Al, 6.48%Cu) was undertaken with the assistance of micro-plasma arc preheating, and welding efficiency as well as joint microstructure and mechanical properties were investigated. Longitudinal…

A finite element model based on a staggered thermo-fluid solution scheme was employed to investigate flow around friction stir welding (FSW) tools, "MORFEO" code simulations were undertaken to predict flow patterns and temperature distribution in th…

Friction stir spot welding (FSSW) experiments were conducted between AA 5052 aluminium alloy and an SP-270C low carbon steel under various process conditions (tool rotation speed 1000-5000 rpm, plunge depth 0.1-0.7 mm), and the microstructure and me…

The material flow of aluminium alloy and steel during dissimilar friction stir spot welding was visualised using zinc tracers and the surface temperature of the flat-tipped tool during stirring was measured by telemetry. Welds were produced in AA505…

Friction stir welding (FSW) was employed to join partially recrystallised AA 5052 (Al, 2.3%Mg) sheet specimens (thickness 5 mm) and the relationship between microstructural development, mechanical properties and process parameters was investigated. …

The swept frequency friction stir spot welding technique was employed to fabricate lap joints in 6061 aluminium alloy workpieces and the influence of process parameters on mechanical properties was investigated. Welding experiments were conducted us…

Microstructural and textural variations in friction stir weld-affected regions of near-alpha Ti-5111 alloys (Ti, 5%Al, 1%Sn, 1%Zr, 1%V, 0.8%Mo) were investigated experimentally and a model incorporating micro-shear banding was proposed to account fo…

The details and methodology of an automatic path planning system for friction stir processing (FSP) of castings are presented, incorporating the means by which operator input is minimised, the limitations and challenges of the automatic programming …

An experimental investigation was conducted into the effects of friction stir processing (FSP) and post-FSP ageing on the microstructure and mechanical properties of Alloy 718 castings. Bead-on-plate welds were fabricated on cast Alloy 718 sheets (t…

A coupled model, comprising a computational fluid dynamic process model, a precipitate evolution model based on classical phase transformation theory and a classical strengthening model, was formulated to investigate the effect of process parameters…

Friction stir welding was employed to fabricate joints in aluminium and magnesium alloys, and the weld zone microstructure and plastic deformation behaviour were investigated. The materials tested were AA 5454-H22 (Al, 2.85%Mg) wrought alloy sheets …

An investigation was undertaken to evaluate friction stir processing (FSP) as a repair technique for AA 7075-T6 aluminium alloys and to examine the mechanical and fatigue performance of the repaired joints for applications such as repair of MIG and …

An experimental investigation was conducted to examine weldability, material thickness, welding speed and joint geometry aspects of robotic friction stir welding (FSW) of aluminium alloy aircraft structures. An ABB IRB7600-500 serial design robot wa…

Weld initiation experiments were undertaken on various Al-Mg(-Si) alloy extrusions to develop fixed-gap bobbin tool designs and process procedures to facilitate friction stir welding (FSW) of sheet specimens as thin as 3 mm. The alloy grades studied…

A multi-physics model for thermal simulation of bobbin-tool friction stir welding was developed assuming a partially sticking condition at the tool-matrix interface, and simulation results were compared with experimental data for welding of AA7449 a…

Friction stir processing (FSP) experiments were undertaken on annealed AISI 420 stainless steel plates (thickness 6 mm) in order to compare three methods for assessing tool wear. The investigations incorporated two tool compositions (WC-Co or polycr…

In relation to the potential of force control friction stir welding (FSW) to produce higher quality weldments, an investigation is presented into the integration of closed-loop force control onto milling machines using popular CNC control systems, f…