TWI Digital Library

The main factors to be considered in the automation and robotisation of friction stir welding (FSW) and the production of one-, two- and three-dimensional welds were identified. A FSW robotic cell was developed and force control algorithms were defi…

A fully Lagrangian smoothed particle hydrodynamics method was employed to simulate the bobbin tool friction stir welding process for aluminium alloys in order to evaluate tool torque and forces as well as material flow for different advancing speeds…

Some numerical and experimental results are presented to illustrate the ability of the SignaStir laser ultrasonic testing system to monitor the occurrence of voids, cavities and lack of root penetration defects during friction stir welding (FSW). A …

The corrosion behaviors of friction stir welded (FSW) joint of 7075 aluminum alloy with and without shot peening treatment (SPT) were investigated by method of acid salt spray. The macroscopical and microscopical corrosion features were observed by …

A device was designed and manufactured to facilitate accurate monitoring of forces, torque and tool temperature during friction stir welding (FSW) and for use as a weld quality indicator in relation to issues such as tool wear, lack of tool penetrat…

Following a summary of the current applications for friction stir welding at Boeing, the Brotje Automation FSW system is introduced. Presentation slides give notes on complex contour FSW in a large work envelope, the characteristics of a robust prod…

Dissimilar joints between AA 6061 aluminium alloy (Al, 0.91%Mg, 0.52%Si, 0.6%Fe) sheets (thickness 2 mm) and zinc-coated HIF-GA (high strength interstitial-free galvannealed) steel (0.002%C, 0.09%Si, 0.47%Mn) sheets (thickness 1 mm) were fabricated …

The large load friction stir spot welding (LL-FSSW) technique was applied to a low carbon steel sheet in order to achieve lap joints at a low temperature, and the microstructure and hardness of the joints were investigated. The composition of the gr…

In the last fifteen years, friction stir welding has developed from a laboratory curiosity to an important fabrication technique for lightweight, lower softening temperature alloys. Industrial implementation of joining magnesium has been limited alm…

A modified Gleeble hot torsion test was used to simulate the stir zone microstructures in types 304L and 310 stainless steels obtained during friction stir welding (FSW). A Gleeble 3800 with a torsion mobile conversion unit was used to perform the t…

A simultaneous double sided corner Ad-Stir fillet stationary shoulder friction stir welding (SSFSW) process was developed for LNG (liquefied natural gas) storage tank construction. The microstructure and mechanical properties of welded joints were i…

The relationship between microstructure and properties, and the influence of microstructure on the fracture toughness of friction stir welded aluminium alloys with weld zone strength undermatching were investigated. Welds were made in 5005-H14, 2024…

The fine scale precipitation in the nugget zone and in the HAZ of a weld in aluminium alloy AA-6082 (Al, 0.7%Mg, 0.5%Mn, 0.9%Si) of thickness 5-10 mm made by friction stir welding (FSW) was examined using transmission electron microscopy. The dissol…

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…

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…

An algorithm and procedure for controlling process zone temperature during friction stir processing are presented. The approach is based on the correlation between weld zone temperature with spindle power. A simplified thermal balance model of the w…

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…

A hybrid friction stir welding (FSW) technique, comprising FSW and a YAG laser (power 2 kW) for preheating ahead of the tool, was developed to decrease tool load and defects. An SS 400 ferrite-pearlite carbon steel (0.16%C, 0.01%Si, 0.49%Mn) was wel…

Butt joints were fabricated by friction stir welding (FSW) in 4340 steel (0.43%C, 0.69%Mn, 0.76%Cr, 1.76%Ni, 0.24%Mo, 0.43%V, 0.16%Cu) and between 4340 steel and Inconel 718 (Ni, 17-21%Cr, 4.7-5.5%Nb, 2.8-3.3%Mo) and their microstructure and mechani…

A combination of laser surfacing and friction stir processing (FSP) was employed to modify a cold-worked AISI D2 tool steel (1.5%C, 11%Cr, 0.83%Mo, 0.36%V) with the aim of clarifying the FSP conditions required to obtain a microstructure with unifor…