TWI Digital Library

The effect of process parameters during the plunge stage of friction stir welding were examined as part of the development of industrialised friction stir welding equipment. The effects of the tool plunging speed and the rotational speed on the maxi…

Abrasion circle and modified refill friction stir spot welding (FSSW) techniques were employed to fabricate dissimilar joints between 6111-T4 (Al, 0.75%Mg, 0.69%Si, 0.75%Cu) and AZ31 (Mg, 3%Al, 1%Zn, 0.5%Mn) alloy sheets (thickness 0.9 mm) with the …

The SCIENZE (Supply Chain Innovation Engineering for Net Zero) Project aims to create a UK based supply chain that is capable of manufacturing the next generation of power electronic components at volumes higher than is currently feasible to do toda…

An ultrasound assisted friction stir welding (UA-FSW) technique was employed to fabricate butt joints in similar Al/Al and dissimilar Al/Mg sheets, and the influence of ultrasonic oscillations on weld zone microstructure and mechanical properties wa…

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…

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…

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…

Artificial intelligence (Al) and machine learning (ML) are major drivers for improving quality of manufacturing process including Friction Stir welding. The specific parameter that has 100% effect on the quality of FSW has not yet been identified, h…

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…

In this study, RFSSW of similar 5052-0 and 6061-T6 aluminum alloys with various thickness from 1.0 mm to 3.0 mm were performed by using cemented carbide tools. Microstructural features and mechanical properties of the joints produced with optimized …

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…

Dissimilar lap joints between ASTM A36 low carbon steel and Inconel 625 (Ni, 21.4%Cr, 9.65%Mo, 3.2%Nb, 2.6%Fe) were fabricated by friction stir welding (FSW) and the effects of process parameters on microstructure and hardness were investigated. FSW…

A simplified friction stir welding (FSW) tool equipped with an adjustable probe was developed, FSW trial results with prototype tools were obtained and were analysed in terms of weldability. The simplified tools were realised by devising shoulders f…

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…

The development of three-dimensional column-type friction stir welding (FSW) equipment for robotic FSW of joints with complex shapes is described. The process requires a large force and precision control for tool penetration. The specification of th…

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…

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 …

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 …

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…