TWI Digital Library

A description is presented of the process flow of a production job based on friction stir welding (FSW) for the serial production of aluminium drying trays for the food industry. FSW joint quality issues (joint impermeability, weld surface quality a…

Vertical and angular truss extrusions made from 6082-T6 aluminium alloy (Al, 0.7-0.74%Mg, 1.04-1.14%Si, 0.53-0.54%Mn) were friction stir welded in a half-overlap configuration to fabricate panels for marine applications and their fatigue performance…

A method was developed to integrate basic force control functionalities into a CNC milling machine for friction stir welding (FSW) by using a standard CNC controller, optimum control parameters for various FSW conditions were identified and the forc…

With regard to the development of a hybrid structure tool holder to facilitate chatter vibration suppression in metal cutting processes, an investigation was undertaken into the use of friction stir girth welding (FSGW) to fabricate dissimilar joint…

With regard to the development of Al-Mg-Sc alloys for aerospace applications, an investigation is presented into friction stir welding (FSW) of thick plates (thickness 35 mm) and thick-walled pipes made from 1570C alloy (Al, 5.7%Mg, 0.29%Mn, 0.2%Sc,…

Butt joints were fabricated in AA 6061-T6 (Al, 0.8%Mg, 0.6%Si) and AA 6082-T6 (Al, 0.62%Mg, 0.99%Si, 0.49%Mn) plates (thickness 6 mm) by friction stir welding, and the tensile and fatigue properties of the weldments were investigated. The microstruc…

Friction stir welding experiments using a W-Re pin tool were undertaken on thermohydrogen processed Ti, 6-6.2%Al, 4.15-4.18%V, 0-0.5%H alloys to investigate the effect of hydrogen content on weldability, and the welded joint morphology, microstructu…

A silicon nitride (Si3N4) tool with a threaded pin was used for friction spot joining of ultralow carbon (0.004-0.01%C, 0.1-0.16%Mn) and DP 590 grade dual-phase high-strength steel (0.06%C, 0.49%Si, 1.23%Mn) sheets, and the microstructure and mechan…

Friction stir welding (FSW) was employed to join various aerospace aluminium alloys, the welded joints were characterised with respect to microstructure, mechanical properties and corrosion resistance, and the effects of post-weld artificial ageing …

Friction stir welding of DH-36 mild steel sheet was evaluated for shipbuilding applications. Butt welds were prepared in sheet of 4.6 mm (0.18 in) thickness using an unthreaded tool (W, 25%Re) rotating at 400 or 500 rpm and travelling at 203 mm/min …

The weldability of 2 mm thickness thixomoulded sheets of AZ91D magnesium alloy by friction stir welding (FSW) was studied as a function of tool rotation speed (880-1750 rpm) and specimen travel speed (50-500 mm/min). The composition of the sheet was…

As part of a study investigating friction stir welding (FSW) as a method for joining the lids on copper canisters for the long term storage of nuclear waste, finite element modelling was used to analyse heat flow and material flow and the developmen…

The effects of tool shoulder size and tilt angle on the formation of weld zones during the friction stir welding of aluminium alloys were studied. Aluminium alloy 5083 (Al, 4.2%Mg, 0.2%Si, 0.6%Mn, 0.15%Fe, 0.09%Cr, 0.09%Zn, 0.06%Cu, 0.02%Ti), an all…

The microstructure and mechanical properties (hardness profiles, tensile strength) of friction stir welded (FSW) joints of ZL114A cast aluminium alloy (Al, 6.5-7.5%Si, 0.45-0.6%Mg), a material of interest for applications in the aerospace industry, …

Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process dev…

Friction stir welding (FSW) is discussed in manufacture of a sports car body made largely of aluminium alloy sheet with some components of cast aluminium or extruded aluminium, and the only steel used is the frame for the windscreen. Advantages are …

Fatigue tests were performed using lap-shear specimens of friction stir spot welded Al, 0.8%Mg, 1%Si alloys. Sheet specimens (thickness 2 mm) were subjected to PWHT of solution treatment and/or ageing. Weld zone microstructure was observed by SEM. F…

The joining of hot rolled aerospace quality AZ31B-H24 magnesium alloy (Mg, 2.5-3.5%Al, 0.7-1.3%Zn, 0.2-1.0%Mn) sheets (thickness 4.95 mm) was investigated using an MTS ISTIR friction stir welding (FSW) machine, the quality of the butt joints produce…

The application of friction stir welding (FSW) to the fabrication of copper backing plates of thickness 6 mm was investigated. The welding conditions, FSW machine development, and mechanical and metallurgical properties of friction stir welded joint…

The design, construction and use of a purpose-built friction stir welding machine for the welding of 15.9 mm (0.625 in) thickness, 1.88 m (74 in) long aluminium alloy 6061-T6 plate and extruded sections to form the side panels of a laser system is d…