TWI Digital Library

A description is presented of the self reacting friction stir welding (SR-FSW) process and the specially designed welding head; results are reported from tests determining the mechanical properties of SR-FSW welds in AA-2219 and AA-2195 aluminium al…

The use of friction stir welding, as an alternative to bolted or riveted joints, for the assembly of Airbus wings is discussed. Issues considered include: cost reduction, weight reduction, joint quality, and enhanced in-service performance. Potentia…

Based on the hypothesis that uniform friction stir weld quality can be produced by maintaining a constant weld zone temperature, an investigation was conducted to develop a feedback strategy and a closed-loop control algorithm to maintain constant t…

With regard to the need for in-process subsurface defect monitoring during friction stir welding (FSW) of aluminium alloys, an investigation is presented into a real-time force measurement system of process output to sense defect formation. Issues d…

An experimental investigation was made on the effect of processing variables and tool material on the microstructure of friction stir welded (FSW) 6 mm thick HSLA-65 steel plate, with the aim of optimising the process variables for enhanced mechanic…

A two-run friction stir welding process was employed to fabricate butt joints in API 5L X80 pipeline steel (0.08%C, 1.86%Mn, 0.16%Cr, 0.01%Ni, 0.18%Mo, 0.03%V, 0.06%Nb) plates (thickness 12 mm) and fracture toughness was determined in the parent met…

With regard to the development of aluminium military vehicles, a report is presented into production level single run friction stir welding (FSW) process parameters for thick plate samples (thickness 12.7-40.6 mm) of 5083, 5059 and 2139 aluminium al…

Friction stir welding experiments were undertaken on commercial SPF (superplastic forming) AA 5083-H19 (Al, 4.43%Mg) and AA 2004 (Al, 6.05%Cu) aluminium alloys, and the effects of tool size, geometry and primary process variables on microstructure a…

Analytical modelling and experimental measurements were undertaken to investigate a dual-loop temperature control algorithm for friction stir processing, incorporating an inner loop to maintain constant power and an outer loop to set the power based…

The feasibility of friction stir welding TIMETAL 21S beta titanium in the annealed condition was investigated. The composition of the alloy is Ti, 14-16%Mo, 2.4-3.2%Nb, 2.5-3.5%Al, 0.15-0.25%Si, max.0.4%Fe, 0.11-0.17%O, max.0.05%C, max.0.05%N, max.0…

The microstructure of joints produced between dissimilar Al alloys by friction stir welding (FSW) was studied. FSW was performed for joining of 5083/6061 Al alloy workpieces of 5 mm thickness using a rotation speed of 1800 rpm and a welding speed of…

In order to develop a method for microjoining by friction stir welding (FSW), micro-FSW trials were conducted on Mg alloy AZ31 (2.97%Al, 0.83%Zn) thin sheets (0.4 mm thickness), and the welding performance was assessed. The micro-FSW system incorpor…

Three recently published finite element studies, modelling friction stir welding (FSW) of different aluminium alloys, were reproduced using ABAQUS software and the results were comparatively assessed. The models considered were as follows: heat tran…

A three-dimensional thermomechanical model of the friction stir welding of aluminium alloy was developed, based on the finite element method, to predict temperature and stress distributions in the workpiece, residual stresses, and the stresses exper…

The design of a polycrystalline cubic boron nitride friction stir welding tool, tool holder and machine for use with high melting temperature materials is described. A polycrystalline cubic boron nitride truncated cone tool tip, capable of working a…

Friction stir welds were made in 4 mm thick sheets of aluminium alloys 2024-T3 and 6013-T6. The stress intensity factor due to residual stresses was determined using the cut compliance method. The residual stress distribution was calculated using th…

Microstructural examination and a root bend test were used to examine the results of friction stir welding in dissimilar welds of aluminium alloys A-5083 (Al, 4.5%Mg) and A-6N01 (Al, 0.6%Mg, 0.65%Si) of thickness 4 mm. Optimum welding parameters (to…

The tensile and bend properties of friction stir welded butt joints in aluminium alloys 2024-T3, 6013-T6 and 7475-T76 were determined, including welds in 2024 and 7475 subjected to PWHT. The ultimate tensile strength, proof stress at 0.2% strain, an…

The feasibility of friction stir welding (FSW) for welding aluminium alloy 7020, used for the construction of light armoured fighting vehicles, was investigated and compared with MIG welding. Two joint configurations were tested: butt welding in 100…

A model which considers heat transfer to both tool and workpiece was developed to predict temperature distributions for the friction stir welding (FSW) process. The model assumes a cylindrical pin generating heat at the interface by friction, and th…