TWI Digital Library

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 …

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…

An investigation is presented into the effects of process parameters on weld quality and defect generation (hooking defects, kissing bonds and top plate thinning) in 7075-T6 aircraft stringers (thickness 1.5 mm) lap-joined on 2024-T3 skins (thicknes…

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…

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,…

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…

Use of friction stir welding (FSW) to replace mechanical fastening in fabrication of an aircraft component in the ROCT Project (Rib One with Crux and Tees) is described. Design is shown of the part, which was assembled using four butt welds from wro…

Dissimilar joints between 2017A-T451 (Al, 4.14%Cu, 0.72%Mg, 0.68%Si) and AlSi9Mg (Al, 8.6%Si, 0.64%Fe, 0.34%Mn, 0.31%Mg) aluminium alloys were fabricated by a friction stir welding process featuring different rates of rotation of the pin and shoulde…

With regard to the occurrence of coarse alpha-Al dendrites, eutectic phase, shrinkage porosity and other defects in cast aluminium alloys, an investigation was undertaken into the influence of different combinations of friction stir processing (FSP)…