TWI Digital Library

Analytical modelling and experimental measurements were undertaken to investigate a dual-loop temperature control algorithm for friction stir processing, incorporating an inner loop to maintain constant power and an outer loop to set the power based…

The influence of tool and plate positions on the friction stir welding of F82H ferritic/martensitic steel (0.1%C, 8%Cr, 2%W, 0.2%V, 0.04%Ta) and austenitic stainless steels 304 and 316 was investigated. Stainless steel compositions were: 304 (0.08%C…

A device was designed and manufactured to facilitate accurate monitoring of forces, torque and tool temperature during friction stir welding (FSW) and for use as a weld quality indicator in relation to issues such as tool wear, lack of tool penetrat…

In the last fifteen years, friction stir welding has developed from a laboratory curiosity to an important fabrication technique for lightweight, lower softening temperature alloys. Industrial implementation of joining magnesium has been limited alm…

A simultaneous double sided corner Ad-Stir fillet stationary shoulder friction stir welding (SSFSW) process was developed for LNG (liquefied natural gas) storage tank construction. The microstructure and mechanical properties of welded joints were i…

The relationship between microstructure and hardness was investigated in friction stir welded aluminium alloy 6063-T5. The alloy thickness was 6 mm. Hardness profiles were measured across the stir zone. The microstructure of the as-welded and postwe…

A review of an experimental study of friction stir welded (FSW) 5456-H1 16 aluminium plate of 19 mm thickness, is presented and the formation of a pre-rotation defect and its effect on the mechanical properties of welds is discussed. Welds were made…

In order to develop a method for microjoining by friction stir welding (FSW), micro-FSW trials were conducted on Mg alloy AZ31 (2.97%Al, 0.83%Zn) thin sheets (0.4 mm thickness), and the welding performance was assessed. The micro-FSW system incorpor…

A production-capable friction stir welding (FSW) process was developed for butt welds (penetration 25.4 mm) in 6061-T6 aluminium alloys, designed specifically for robotic welding of large box assemblies requiring many multi-dimensional weld paths, a…

The development and use of friction stir powder processing (FSPP) to overcome defect formation and to control mechanical properties is discussed and FSPP of AA 1050 aluminium (Al, 0.06%Si, 0.34%Fe, 0.02%Cu) is reported. In FSPP, powder with a contro…

A numerical model of the friction stir welding (FSW) process was developed by employing finite element analysis of a non-Newtonian fluid to evaluate plastic deformation and heat generation of the weld material, and was applied to the design of tool …

Dissimilar butt joints were fabricated between two aluminium alloys, 2017A-T451 (Al, 4.14%Cu, 0.72%Mg) and AlSi9Mg (Al, 8.6%Si, 0.31%Mg), by friction stir welding (FSW) using a dual-speed tool and their microstructure and mechanical properties were …

An investigation was carried out in order to examine the feasibility of producing friction stir welded FSW T-joints using the corner fillet geometry. A specific tool comprising a rotating pin (made of MP159) with a 45 degree inclination to the two p…

An investigation was undertaken to examine the effect of adding aluminium to magnesium on the strength of dissimilar joints between steel and magnesium fabricated by friction stir welding. The materials studied were pure 3N magnesium, AZ31 (Mg, 2.9%…

Friction stir welding (FSW) was carried out on A-6N01-T5 aluminium alloy of thickness 15 mm in various restraint conditions, and the amount of deformation before and after welding was investigated. Vertical distortion and lateral shrinkage of the we…

Friction stir processing (FSP) was employed to fabricate oxide dispersion strengthened copper composites and the microstructure and mechanical properties of the materials were investigated in order to clarify the effect of process parameters on mate…

Friction stir welding tool developments to enhance the range of process applications, welding speed and quality are described. The scroll shoulder tool has a shoulder profile which moves surface material towards the probe. It improves surface qualit…

To overcome the limitations associated with conventional friction stir welding, particularly for complex shaped large structures, the bobbin tool technique was developed and demonstrated on various aluminium alloys (4-15 mm thickness range), the tec…

A spot FSW robot system was developed and used to weld lap joints in aluminium alloys (used mainly in car body assembly) and the static strength of the welded joints was compared with resistance spot welded joints. A prototype spot FSW gun was combi…

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…