TWI Digital Library

Results are presented from tests carried out to determine the mechanical and corrosion properties of friction stir welds in sheets of thickness 4 mm of two aerospace aluminium alloys AA-6056 and AA-6013. The specimens included alloys in the T6 condi…

Friction stir welding developments, equipment, and applications for the joining of aluminium alloys, particularly for automotive applications, are reviewed. Body in white automotive applications include aluminium alloy tailor welded blanks and the m…

An experimental study was carried out to characterise the types of defect which may occur in friction stir welding (FSW) when operating outside the standard processing window and to determine the causes of these defects. Friction stir welds were mad…

Based on lessons learned from the MegaStir research programme devoted to friction stir welding (FSW) of high temperature alloys and with the aim of producing high quality, defect free welded joints while maximising tool life, a report is presented i…

Friction stir welding (FSW) is a solid-state joining method, being well-known to be suitable particularly in joining of aluminum in all alloy and manufacturing forms. The technological advantages of FSW can be also expanded to high-strength steel ma…

The forces exerted on the pin of a friction stir welding tool with a variable length pin (retractable pin-tool) were measured whilst welding aluminium alloy 2195 plate of 8.4 mm thickness, to develop a closed loop control system. Forces were measure…

Friction Stir Welding (FSW) is a relatively new technique which utilizes frictional heating combined with a forging pressure to produce virtually defect-free high strength bonds. Although considerable experimental work has been reported in the liter…

An finite element method (FEM) model, considering variables such as tensioning level, heat input and sheet geometry but ignoring mechanical tool effects, was developed to investigate the efficacy of the mechanical tensioning technique for controllin…

With regard to the fabrication of closure welds for used fuel containers, a series of experiments was undertaken to demonstrate the feasibility of creating defect-free partial penetration welds by friction stir welding (FSW) in A516 Grade 70 steel (…

The application of suitable friction stir welding (FSW) tools and procedures to common structural geometries in industry, with emphasis of FSW of hard metals including steel, titanium and nickel based alloys in butt, T-joint, corner joint and circum…

A friction stir welding (FSW) procedure using a W-Re alloy tool, magnetic welding fixture and a high-speed steel backing bar was developed for application to precipitation-hardened martensitic stainless steel (13.7%Cr, 7.1%Ni) thin sheet (thickness …

Friction stir welding experiments were undertaken on thin sheet specimens (thickness 0.8 mm) of 5754-H111 alloys (Al, 2.7%Mg) in a butt joint configuration, and the influence of process conditions on microstructural, mechanical and corrosion propert…

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…

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) has been used to weld aluminum alloys such as 7075 to 7075, which is considered not weldable by most other methods. In this application FSW was used to join two dissimilar aluminum alloys 7075 and 6N pure copper in a lap …

An extensive study of friction stir welding (FSW) of HSLA-65 steel plate (thickness 6 mm) was undertaken, incorporating defect-free friction stir butt welding at a travel speed of 3.4 mm/s, the achievement of low/no distortion FSW by employing appro…

A method investigated by Sweden for storage of nuclear waste in copper canisters sealed using friction stir welding (where EB welding has been used before) is described. Topics include: Nimonic 105 and Densimet sintered tungsten alloy tool; welding …

With regard to the occurrence of residual oxide defects associated with friction stir welding (FSW) of aluminium alloys, an investigation is presented into a possible alternative mechanism for oxide formation within the weld nugget involving enhance…

Extruded AZ31 (Mg, 3%Al, 1%Zn) alloy plates (thickness 6 mm) were joined by one-run or two-run friction stir welding (FSW) and the microstructure, mechanical properties and residual stress characteristics of the welded joints were investigated. FSW …