TWI Digital Library

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…

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 …

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…

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 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…

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…

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…

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…

Two initiatives are presented to develop friction stir welding (FSW) and friction stir spot welding (FSSW) design data for the aerospace industry: a path independence initiative for FSW butt joints and qualification of FSSW welds for lap joints as i…

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 technique was developed to fill the exit hole during the retraction phase of a friction stir welding (FSW) sequence which, by using existing equipment functionality and designing a hollow FSW tool, syringe-type delivery system and pre-loaded alumi…

With regard to the use of friction pull plug welding to close out the termination hole associated with pin tool retraction during friction stir welding of circumferential welds in pressurised cryogenic propellant tanks, an investigation is presented…

A scanning nonlinear acoustic NDT method was employed to detect the presence of kissing bonds in a friction stir welded 2000 series aluminium alloy and experimental results were validated using coupons taken from the scan area and inspected by optic…

Based on a dynamical control-low stress no distortion (DC-LSND) methodology, an array jet impingement heat sink apparatus was designed to facilitate reductions of residual stress and distortion in friction stir welding (FSW), and test results were o…

Friction stir welding (FSW) is broadly recognized as an efficient solid-state welding technology to join light metal alloys and is worth considering expanding its technological benefits for joining materials with different chemical compositions and …

An investigation was undertaken to examine the use of an industrial serial robot incorporating dual loop force/position control to reduce the investment cost and increase process flexibility in friction stir welding (FSW) by compensating the lateral…