TWI

Tensile testing was used to characterise and compare the fracture locations and their influencing factors for a number of friction stir welded aluminium materials (AA-1050, AA-2017, AA-6061). Friction stir welding was carried out on sheets of thickn…

A 3D computational fluid dynamics model was developed to conduct numerical simulations of heat generation, material flow and temperature profiles during reverse dual-rotation friction stir welding, a process variant in which the tool pin and the ass…

SiC particle reinforced 2124Al metal matrix composite (MMC) plates (thickness 8 mm) were joined by friction stir welding (FSW) and the relationship between process parameters, weld defect formation and joint mechanical properties was investigated. T…

The microstructure and postweld heat treatment of friction stir welds in age hardening aluminium alloys were investigated. Aluminium alloy plate (2014-T6 and 7075-T6 and -T651) of thickness 6.35 mm (0.25 in) was friction stir welded and the joints s…

Physical simulations were undertaken on cylindrical specimens of 304L stainless steel using a "Gleeble 1500" thermomechanical simulator in the form of hot axial compression tests so that the material underwent similar heating and cooling profiles to…

With regard to the application of wear resistant surface layers on chosen substrates, an investigation is presented into the deposition of cermet (WC, 10%Co, 4%Cr or Cr3C2-NiCr) and oxide (Al2O3) coatings onto AA 5083 aluminium alloy substrates by c…

A report is presented into the challenges faced when developing thermal, thermomechanical and flow models of the friction stir welding process, such as the evolution of predictive models, a method to find the correct contact state variable, and the …

A control concept for friction stir welding (FSW) of structural steels was developed based on a closed loop architecture that limits the heat input during the welding process according to the continuously monitored value of the magnetic permeability…

The microstructure of joints produced between dissimilar Al alloys by friction stir welding (FSW) was studied. FSW was performed for joining of 5083/6061 Al alloy workpieces of 5 mm thickness using a rotation speed of 1800 rpm and a welding speed of…

A review is presented of the state-of-the-art of industrial friction stir welding (FSW) mass production, current trends, challenges and market demands as well as the potential of high speed complex contour welding on multi-axis FSW machinery with re…

An adjustable tool was employed during friction stir welding (FSW) of A1050 pure aluminium sheets (thickness 5 mm) and the effects of the tool shoulder and probe on the stir zone shape and defect formation were investigated by changing the rotationa…

Friction stir processing (FSP) was employed to repair casting defects such as shrinkage cavities and porosity in nickel aluminium bronze, and the corrosion behaviour of the processed material was examined through short-term and long-term testing and…

In order to understand the complex interactions between deformation, recrystallisation and precipitation induced during friction stir welding, two aluminium alloys were studied: a work hardened 5251-O alloy (Al, 2.2%Mg) and a precipitation hardened …

The friction stir welding of lap joints of aluminium alloy 6061 sheet of 3 mm thickness was monitored using a variety of sensors, to establish systems for weld quality control. A triaxial dynamometer measured the forces on the workpiece in three per…

The effects of friction stir welding (FSW) on the corrosion resistance of aluminium alloys 2014A and 7075, both welded in the peak aged T651 condition, were studied. The effects of postweld heat treatment (retrogression and reageing treatment) were …

The microstructure, mechanical properties and fatigue behaviour of friction stir welded (FSW) and MIG welded butt joints in aluminium alloy 2519-T87 (Al, 5.3-6.4%Cu, 0.1-0.5%Mn, 0.02-0.1%Ti) plate of 25.4 mm thickness were compared. Friction stir we…

A Granular Computing (GrC) Neural-Fuzzy (NF) modelling approach that can learn relational data descriptions from a minimum number of experimental data is proposed for finding optimal process operating windows in friction stir welding (FSW). Research…

Weld production tests were conducted using friction stir welding (FSW) and MIG processes for the production of aluminium panels. Production times were measured using a 2 m long double-skinned EN AW 6005 A-profile joint as the basic unit. Welding spe…

The thermal stability of the microstructure in the plastically deformed region of aluminium alloy friction stir welds was investigated. Alloys 6082-T6 (Al, 0.62-0.70%Mg, 0.95-1.05%Si, 0.50-0.57%Mn, 0.15-0.23%Fe) and 7108-T79 (Al, 5.20-5.70%Zn, 0.70-…

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…