TWI

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 …

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…

The design and construction of a prototype fixture and a corner fixture for making 90 degree corner joints in aluminium alloys by friction stir welding (FSW) are described. The requirements for a FSW weld fixture are outlined. The fixtures were test…

The friction stir welding of copper for the production of spent nuclear fuel storage disposal canisters was investigated. Initial trials were conducted on UNS-C10100 plate of 10 mm thickness. The high temperatures required the use of a sintered tung…

Friction stir welding (FSW) experiments were undertaken on commercially pure titanium and Ti, 6%Al, 4%V alloy sheets (thickness 1.2 and 1.25 mm, respectively), the microstructure of the weldments was examined and the wear mechanisms of the welding t…

An investigation is presented into the development of polycrystalline cubic boron nitride (PCBN) and composite W-Re alloys with PCBN and diamond reinforcement as tool materials for friction stir welding of high temperature materials. High-pressure, …

An experimental investigation was conducted into the friction stir welding (FSW) of 6 mm thickness aluminium alloy AA6082-T6 using welding conditions slightly outside the common process window. The microstructure, quality and fatigue strength of the…

The development and experimental validation of a finite element model ("DEFORM-3D" software) for friction stir welding (FSW) of 7XXX series aluminium alloys (e.g. AA-7075) with varying pin angle and advancing speed are described, and application of …

A presentation is made of a successful demonstration of the friction stir welding (FSW) of steel capabilities in a shipyard production facility, summarising the equipment, fixturing and tooling requirements. HSLA-65 steel panels (17m x 2.4m), 6mm th…

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…

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…

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, …

An investigation is presented into the use of a friction stir welding/forging process to fabricate tee and I-beam shapes with integral radial shaped fillets, the optimisation of process parameters for different alloys and shapes, and the results of …

Friction stir welding (FSW) experiments were undertaken on sheet specimens (thickness 5 mm) of 5454-H111 aluminium alloys and the relationships between process forces, spindle power and tool geometry were investigated. Twelve FSW tools with specifie…