TWI

An experimental investigation was undertaken into the preparation and mechanical properties of two candidate substitutes to MP 159 Ni-Co alloy as tool materials for friction stir welding of high strength aluminium alloys. The alloys studied were "Ae…

Dissimilar butt and lap joints between AA 5083-H111 or AA 6082-T6 aluminium alloys and copper were fabricated by friction stir welding and morphological, metallographic and structural analyses were undertaken on weldments made under a range of proce…

In relation to the development of friction stir welding (FSW) technology for railway rolling stock manufacture in China, an investigation is presented into the microstructure and mechanical properties of AA 6005A-T6 aluminium alloy (Al, 0.56%Mg, 0.7…

Aluminium alloy fusion welds were modified by friction stir processing (FSP) as a function of FSP location and tool design, and differences between the FSP locations and tools were quantified by microstructure and mechanical property measurements (u…

The incorporation of strips of copper foil in friction stir welded aluminium alloy plate was evaluated for flow visualisation without disturbing the welding process. The strips, of 0.1 mm thickness, were placed in various longitudinal and transverse…

Guidance notes devised for Lloyd's Register of Shipping surveyors for use in the quality assurance of friction stir welded aluminium alloys are presented.The notes cover: welding equipment, materials welded, and welding requirements (weld qualificat…

In relation to the development of "AIRWARE" technology based on Al-Cu-Li alloys for aircraft structural parts, a report is presented into the friction stir welding (FSW) of "AIRWARE" 2050 alloys, mechanical characterisation of welded joints, and ind…

A conceptual model was developed to describe the relationship between process variables and physical properties such as spindle torque, heat generation and workpiece temperature distribution for friction stir welding of aluminium alloys. The materia…

A series of models was used to study weld formation in 6000-series aluminium alloy in the friction stir welding process. Weld formation was considered as three separate thermomechanical processes: coupled friction heat generation; plastic flow slip …

This paper describes the joining criterion for lap joining of dissimilar metal materials of aluminum and stainless steel by friction stir. A criterion for evaluating the joined state or non-joined state is proposed, which is led by the concept based…

An experimental and numerical analysis of the wear of a polycrystalline boron nitride (PCBN) friction stir welding (FSW) tool is overviewed as presentation slides. Topics highlighted include: FSW plunge trials of EH46 shipbuilding steel at a plunge …

A friction stir welding (FSW) methodology incorporating laser tracking and constant force control technologies was developed in order to fabricate large, thin-walled aircraft floor structures. The material chosen for study comprised sheet specimens …

The CFD (computational fluid dynamics) technique was employed to develop a numerical model of friction stir welding (FSW) of DH36 steel (0.16%C, 1.2%Mn, 0.02%Cr, 0.02%Nb, 0.04%Al, 0.03%Cu) plate (thickness 6 mm) under low and high welding speed cond…

Quantification approaches applied to phase space data generated from friction stir welding aluminium alloys under varying process conditions are reported. A multi-step, micro-wormhole, non-destructive evaluation phase-spaced, (PS) algorithm that com…

An overview is presented of the twenty year history and technological developments relating to the application of friction stir welding (FSW) to aluminium alloy railway car body shells. Issues discussed include the history of railway car body shell …

A report is presented into the development of a refill friction stir spot welding (FSSW) robot system, performance evaluation with respect to FSSW of aircraft aluminium alloys, and fabrication of full-scale aircraft production components. The FSSW r…

The friction stir weldability of the dissimilar materials copper and aluminium alloy was studied, assessing the effects of different process parameters (rotation and traverse speeds, rotation direction (Cu or Al on advancing side), displacement and …

Preliminary results from a 3-dimensional heat and material flow computer simulation program for friction stir welding are given and compared with experimental observations. The simulation is based upon solutions of Navier-Stokes equations and nonlin…

Thermodynamic modelling and experimental measurements were employed to investigate the influence of intermetallic compound formation on the shear strength of dissimilar joints between an aluminium alloy and ultra-high strength steel fabricated by fr…

A high force, multi-axis friction stir welding (FSW) machine was employed to perform one-run welding experiments on thick plates (thickness 75 mm) of AA 6082-T6 alloys, and the hardness, microstructure and crystallographic texture of the joints were…