TWI Digital Library

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…

The StiRoLight Research project (carried out in conjunction with SAAB, ESAB and Volvo) to investigate the use of an industrial robot for friction stir welding of aluminium alloys in the automobile industry, is outlined and studies of path deviations…

Ultrafine grained test pieces of aluminium, copper and steel produced by the accumulative roll bonding process were friction stir butt welded at various revolutionary pitches, and the microstructures and mechanical properties (tensile strength, Vick…

A discussion is presented on research studies carried out to develop friction stir welding (FSW) as a method for the production of thick (50.8-76.2 mm; 2-3 in) aluminium alloy 7050 tailored blanks suitable for use in the aerospace industry. Single r…

The test results are reported for preliminary trials of the feasibility and benefits of applying angular reciprocating (reversal within one revolution) or rotary reversal (reversal after one or more revolutions) motion to the tool during friction st…

Thick section friction stir welds were made in 25.4 mm (1 in) 5083-H131 and in 18.4 mm 2195-T8P4 aluminium alloy plates by single-pass friction stir welding (FSW) using new welding tool designs. The alloys are used for aerospace applications. The sh…

Aluminium alloy A6N01-T5 (Al, 0.63%Mg, 0.53%Si) hollow extrusions suitable for joining by friction stir welding, to be used in the generation of Japanese railway rolling stock, were designed, and the static and fatigue tensile strength of joints wer…

Friction stir welding of UK Ministry of Defence Def Stan 95-22 7017 aluminium alloy (Al, 4.5%Zn, 2.0%Mg) armour plate was evaluated by studying the mechanical properties and cracking of welded joints. Initially plate of 10 mm thickness, locally redu…

A new "stop action" technique was used to investigate material flow during the friction stir welding of aluminium alloy 6061-T6 plate of thickness 6.4 mm (0.25 in). The technique involved stopping the welding process and examining the microstructure…

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…

The modification of a thermally sprayed cemented layer of WC-CrC-Ni (WC-20%CrC-7%Ni) and WC-Co (WC-12%Co) using friction stir processing (FSP) was investigated. Layers of WC-CrC-Ni and WC-Co were sprayed onto SKD61 substrate (17 mm thickness) by HVO…

Dissimilar lap joints were fabricated in various aluminium alloys by conventional friction stir welding (FSW) and a hybrid FSW process involving two adhesive systems, and the influence of thermal degradation of adhesive on the microstructure and mec…

An investigation was made of approaches to tool design for the self reacting pin tool (SRPT) (bobbin tool) to mitigate the effects of friction stir welding owing to enlarged grains that occur in large structural extrusions, in order to yield accepta…

A friction stir spot welding (FSSW) process was employed to fabricate dissimilar joints between an AA 5754 aluminium alloy and an AZ31 magnesium alloy in a lap joint configuration using a Zn layer at the interface to suppress intermetallic formation…

A brief review is presented of the RIFTEC welding job shop, a major supplier for friction stir welded components in Germany, and Hammerer Aluminium Industries (HAI) in Austria and some of their applications to railway, automotive and electronic indu…

A review is presented of FSW (friction stir welding) tool design parameters and their relationship with heat generation, material flow and weld quality, including discussions of interaction mechanisms between tool and specimen, typical tool designs,…