TWI Digital Library

Based on a friction model incorporating the dynamic coupling between friction and material flow in heat transfer and fluid flow models, a computational fluid dynamics (CFD) methodology was employed to study material flow during friction stir welding…

Experiments were undertaken to investigate the evolution of welding forces and torque generated during robotic friction stir welding of circular and semicircular butt welds in 6082-T651 aluminium alloy plates (thickness 6 mm). Welding was performed …

With regard to the application of AA 2219 aluminium alloys to space launch vehicle propellant storage tanks, an investigation is presented into the influence of process parameters (tool rotational speed, shoulder downward force and weld transverse s…

An experimental investigation was undertaken to study the effects of different pin profiles (threaded conical, square, pentagon and hexagon) and the same process parameters on temperature distribution around the tool and resulting microstructure dur…

A feasibility study was undertaken to investigate the use of friction stir welding to join B4C particle reinforced Al metal matrix composite plates (thickness 8 mm) that form the neutron absorber tubes of the basket of a spent nuclear fuel cask. Wel…

An experimental procedure based on a Gleeble 3500 thermomechanical testing system was developed to investigate hot deformation parameters in the high temperature range for application to friction welding related processes. Experiments were conducted…

In relation to the production of local metal matrix composites (MMCs) by friction stir processing (FSP), an investigation was undertaken into the influence of tool geometry and process parameters on the shape of the nugget zone and the assessment of…

Butt joints were fabricated between A6063 aluminium alloys and S45C mild steel by friction stir welding (FSW) and the effect of material flow on the weld interface formation was investigated using the stop action technique. FSW experiments were unde…

A review is presented of the application of CFD (computational fluid dynamics) to numerical modelling of the friction stir welding (FSW) process, incorporating coupled physical phenomena such as heat generation, heat transfer and metal flow. Issues …

The effects of multiple overlapping friction stir weld runs (with 100% overlap) on the welding parameters and weld properties during the repair of high-strength AlCuMgZn alloy were investigated. Square butt welds were made in 7050-T7451 alloy (Al, 6…

Precipitation hardened copper alloy sheets (thickness 2 mm) containing Cu, 0.9-1.2%Cr, 0.06-0.09%Zr were joined by friction stir welding (FSW), process parameters were optimised to realise defect-free joints, and the microstructure and mechanical pr…

To meet the needs of lightweight automobile design to join thin steel structures to thicker aluminium sheets, two joint geometries for high-strength friction stir welding (FSW) of dissimilar and unequal thickness sheets were developed: one involving…

A review is presented of various models developed to understand the effects of thermal cycles and metal flow behaviour on the microstructure and properties of welded joints fabricated by friction stir welding of steel, and a comprehensive numerical …

Two initiatives are presented to develop friction stir welding (FSW) and friction stir spot welding (FSSW) design data for the aerospace industry: a path independence initiative for FSW butt joints and qualification of FSSW welds for lap joints as i…

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…

A review is presented of the development programme to achieve a production-ready procedure to manufacture copper canisters for Swedish radioactive waste storage using friction stir welding (FSW) for encapsulation, incorporating adaptive thermal mana…

A geometric feature, termed the "Wiper", was developed to improve the weld track surface finish produced by friction stir welding (FSW) and processing tools with scrolled shoulders, and experiments were undertaken to investigate the influence of "Wi…

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,…

Friction stir welding (FSW) experiments were conducted on X52 and X60 pipeline steel specimens (outer diameter 324 mm, wall thickness 6.35 mm) and weldment integrity was evaluated by metallography, NDE and mechanical properties characterisation. Wel…