TWI Digital Library

In battery cell assembly, tab-to-busbar joint connections are usually done by welding incompatible metals such as Ni and Al. Micro friction stir welding is becoming increasingly popular as a joining method due to its solid-state nature. Nonetheless,…

Details are reported of application of friction stir welding (FSW) to manufacture of double skin bodies of railway carriages for commuter lines in Japan. A "defect free" FSW process is used to weld double skin panels of length 25 m using hollow extr…

Friction stir welding (FSW) was employed to fabricate overlap joints in thin AA 7075-T6 aluminium alloy (Al, 5.1-6.1%Zn, 2.1-2.9%Mg, 1.2-2%Cu) sheets (thickness 0.8 mm) coated with an anticorrosive aluminium layer and the microstructure and mechanic…

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…

Local stress-strain curves were determined from an array of spherical indents on the cross-section of the joint of a friction stir welded (FSW) high strength aluminium alloy AA 2198 sheet, in order to characterise the mechanical properties of differ…

A review is presented of process development work undertaken with regard to a machine concept assessment and the realisation of a fully 3D-capable 5-axis parallel kinematic friction stir welding machine, a so-called pentapod, suitable for large and …

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…

Artificial Intelligence algorithms based on machine learning approaches have recently found application in joining and welding, e.g., for the optimization of process parameters or the prediction of resulting mechanical properties. The importance of …

Friction stir spot welding experiments were conducted on dissimilar metal joints between AA5052 aluminium alloy and three kinds of zinc coated steel, and weldability analysis, microstructure observations and mechanical tests were undertaken. The coa…

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…

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…

Butt welding experiments were undertaken to investigate the feasibility of joining a metal matrix composite (MMC), comprising an Al-10%Si matrix and 20 vol.% SiC particles, to an AA-6063-T5 alloy by friction stir welding (FSW). Optimum process param…

Friction stir butt welding experiments were conducted on S45C medium carbon steel sheets (thickness 1.5 mm) under various conditions and the microstructure and mechanical properties of the welded joints were investigated. Single run butt welding was…

An experimental investigation is presented into the precipitation and hardening mechanism during FSW (friction stir welding) of Ni model alloys (Ni, 20%Cr, 2%Al, 2%Ti and Ni, 20%Cr, 3%Al, 3%Ti) in which Al and Ti contents were varied to control the …

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…

Dissimilar lap joints between AlSi10MgMn aluminium alloy sheets (thickness 3 mm) and Al-Si coated Usibor 1500 22MnB5 hot stamped boron steel sheets (thickness 1.8 mm) were fabricated by friction stir spot welding (FSSW) under different processing co…

A 3D thermomechanical model, incorporating knowledge of residual distortion and stress, was developed as a finite element tool for simulation and optimisation of clamping situations in friction stir welding (FSW) and experiments were undertaken on A…

An investigation was undertaken to determine the strength and fracture toughness of joints fabricated by friction stir welding (FSW) in commercial X65 (0.07%C, 1.56%Mn, 0.06%Nb, 0.013%Ti) and X80 (0.05%C, 1.52%Mn, 0.26%Cr, 0.26%Cu, 0.1%Nb and 0.07%C…

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…

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…