TWI Digital Library

A discussion is presented on the development of a FSW process for the welding of thin gauge aluminium alloy lap joints in the fuselage and wing sections of the Eclipse 500 twin-engine jet aircraft. The issues of pin tool geometry for use on lap join…

The effects of friction stir welding (FSW) on the corrosion resistance of aluminium alloys 2014A and 7075, both welded in the peak aged T651 condition, were studied. The effects of postweld heat treatment (retrogression and reageing treatment) were …

The origin of the lines of micrometre sized oxide particles observed in aluminium alloy friction stir welds was investigated. Butt and bead on plate welds were prepared using 6 mm plate of aluminium (99.999%Al and 99.5%Al) and aluminium alloy 6056 (…

Preliminary results from a 3-dimensional heat and material flow computer simulation program for friction stir welding are given and compared with experimental observations. The simulation is based upon solutions of Navier-Stokes equations and nonlin…

In this study, the mechanical properties and metallurgical joining interface of aluminum alloy and various strength steel joints by scrubbing refill FSSW (Sc-RFSSW) were investigated. It was shown that Sc-RFSSW provides higher joint strength than co…

Dissimilar lap joints between AA 6061-T6 (Al, 1.01%Mg, 0.59%Si) and A356 (Al, 7.02%Si) aluminium alloys were fabricated by friction stir welding (FSW) and the influence of process conditions on joint microstructure evolution and mechanical propertie…

An investigation was undertaken to examine the interactions, required process adjustments and resultant joint properties associated with conventional and robotic stationary shoulder friction stir welding (SSFSW) for scaled tool geometries. In order …

A rotating data logger system was developed to investigate the influence of process parameters on tool tip temperature during friction stir spot welding (FSSW) of AA 6061-T6 and 5083-O aluminium alloy lap joints. The data logger was designed to rota…

AA 6063-T5 aluminium alloy L-shape stringers (thickness 2 mm) were friction stir welded in an overlap configuration positioned over AA 2024-T3 sheets (thickness 3 mm) using various process conditions and three different tool designs with respect to …

Dissimilar joints between AA 6063 aluminium alloy and S45C steel were fabricated by friction stir welding and the growth behaviour of intermetallic compounds (IMCs) at the weld interface during PWHT was investigated. Welding was performed at a rotat…

Physical simulations were undertaken on cylindrical specimens of 304L stainless steel using a "Gleeble 1500" thermomechanical simulator in the form of hot axial compression tests so that the material underwent similar heating and cooling profiles to…

Friction stir welding experiments were undertaken on Al-Li alloys for application to C919 passenger aircraft fuselage panels, and the microstructure and mechanical properties of the welded lap joints were investigated. The materials comprised 2060-T…

The microstructure, hardness, tensile strength and fracture toughness of friction stir welds in cryogenic tanks made from standard AA2219 AlCu alloy and advanced AA2195 AlCuLi alloy (5 mm thickness) were investigated. AA2195 has relatively low densi…

Friction stir lap welding of aluminium alloy to magnesium alloy was investigated, emphasising the tensile strength, fracture location in the joint and microstructure evolution in the weld under different welding heat inputs. Dissimilar joints betwee…

Thick sheets (thickness 5.4 mm) of a ferritic stainless steel (18.33%Cr, 1.81%Mo, 0.2%Nb) were joined by friction stir welding with optimised process parameters (rotational speed 200 rpm, welding speed 100-160 mm/min) and the microstructure and mech…

An empirical process model to estimate tool shoulder temperature for different materials and friction stir welding (FSW) conditions is described that incorporates a design of experiments method and linear regression analysis (MATLAB software) with c…

To better understand the heat generation, temperature distribution and material flow during friction stir welding (FSW), experiments, including some with a pin breaking technique, were undertaken on two aluminium alloys (5083-O (Al, 4.5%Mg) rolled p…

The influence of the tool profile and short welding cycles on the friction stir spot welding (FSSW) of thin aluminium sheet was investigated using several different techniques including high-resolution x-ray tomography. Weld quality, microstructure,…

An investigation is presented into the fatigue characteristics of friction stir welded (FSW) lap joints made from artificially aged Al alloy 6082 (Al, 0.6-1.2%Mg, 0.7-1.3%Si) using a tool based on the "Triflute" concept with either convex or concave…

A 16-run screening design of experiments (DOE) was conducted to analyse the effects of nine factors during friction stir welding on process forces, temperatures and shoulder depth. The factors were spindle speed, feed rate, plunge depth, pin length,…