TWI Digital Library

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…

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…

Advances in low cost, rapidly re-configurable fixturing and support tooling for the production of complex curvature parts by friction stir welding are described. An Intelligent Friction Stir Welding (IFSW) path planning algorithm developed by the So…

Developments in non-destructive techniques for detecting small defects in friction stir welds in thin aluminium plates in aerospace applications are considered. The principles of ultrasonic phased-array technology and eddy current array technology a…

Flow in friction stir welds in Al-Cu-Li aluminium alloy 2195-T8 plate (8.1 mm thickness) was observed by placing markers in the faying surface prior to welding. Markers of aluminium alloy 5454-H32 (1.8 x 2.7 mm) were placed in slots milled in the fa…

This research studies a hybrid method of manufacturing of porous alloy/ foam or functionally graded porous alloys with the help of a hybrid process of friction stir processing followed by microwave post-processing. The manufacturing productivity of …

The friction stir welding (FSW) manufacturing technology of large aluminium extrusions for rail, automotive and aerospace applications was optimised. Tensile strength, impact value, hardness and microstructure were investigated in friction stir weld…

The development of cryogenic tank domes for gas tanks for carrier rockets using friction stir welding (FSW) and high strength aluminium alloys of the 2xxx series is outlined. The verification of an existing NC-controlled milling machining centre (Ca…

The effects of laser surfacing on the microstructure and corrosion properties of friction stir welds in 6.34 mm (0.25 in) thickness plates of aluminium alloys 2024-T351 and 7010-T7651 were studied. Specimens were laser surfaced using an excimer lase…

Friction stir welded joints, produced in an extruded profile of aluminium alloy 6082-T6 using run on and run off plates, were evaluated by measurement of mechanical properties. Plate of 6 mm thickness was welded using a range of process parameters, …

Aluminum 6xxx extrusions are commonly joined with either friction stir welding (FSW) or fusion welding into large-sized assemblies. The assemblies are typically deployed to service in as-welded condition. Mechanical performance of naturally aging we…