TWI Digital Library

A short review is presented of the development of a friction stir welding process for steel and other hard metals using W-Re tool materials to produce repeatable, thick-section welds with minimal tool deformation. Issues discussed include: W, 25%Re …

Following a summary of the current applications for friction stir welding at Boeing, the Brotje Automation FSW system is introduced. Presentation slides give notes on complex contour FSW in a large work envelope, the characteristics of a robust prod…

A modified Gleeble hot torsion test was used to simulate the stir zone microstructures in types 304L and 310 stainless steels obtained during friction stir welding (FSW). A Gleeble 3800 with a torsion mobile conversion unit was used to perform the t…

Friction stir welded joints in 2024-T351 Al-Cu-Mg alloy were subjected to fatigue testing to evaluate the suitability of this welding process for aircraft manufacture. Aluminium alloy (Al, 3.8-4.9%Cu, 1.2-1.8%Cu, 0.5%Si, 0.5%Fe, 0.2%Zr) of 6.35 mm (…

Friction stir welding (FSW) experiments were undertaken on Cr-containing carbon steels (0.22%C, 0.5%Mn, 0-4%Cr) and the influence of Cr content on joint microstructure and mechanical properties was investigated. FSW was conducted at a tool rotationa…

A three-dimensional thermomechanical model of the friction stir welding of aluminium alloy was developed, based on the finite element method, to predict temperature and stress distributions in the workpiece, residual stresses, and the stresses exper…

Different aluminium alloys were joined by friction stir welding (EN AW-5754-H14 to sheets of the same material, extruded profile EN AW-6063-T6 sheets to high pressure die cast EN AC-46000) and characterised by x-ray and microscopy studies, and the m…

The weldability of magnesium alloys by friction stir welding was studied using three die-cast alloys of thickness 6 mm (AM50 and AM60 Mg-Al-Mn alloys; AZ91 Mg-Al-Zn alloy) and one wrought alloy of thickness 6.4 mm (AZ231 Mg-Al-Zn alloy). Surface app…

3-point fatigue bending tests and finite element method simulations were employed to study the fatigue performance of combined lap-butt joints fabricated by friction stir welding in 6005A-T6 alloy (Al, 0.61%Si, 0.54%Mg) extruded profiles for railway…

The feasibility of short-cycle friction stir spot welding for joining thin sheet aluminium alloys and steels, both galvanised and ungalvanised, was evaluated. Welds were made between 6111-T4 AlMgSi alloy (Al, 0.75%Cu, 0.25%Fe, 0.75%Mg, 0.2%Mn, 0.69%…

The results of quality assessments, based on visual examination, mechanical testing, analysis of weld structures and hardness testing, of both similar and dissimilar friction stir welded (FSW) joints of aluminium casting alloys EN AC-42100, EN AC-43…

To assess the feasibility of friction stir welding of Ti-6Al-4V alloy (thickness 5 mm), appropriate pin tool material and processing parameters were determined, thermal and environmental management systems were tested, and both A- and B-basis design…

Dissimilar butt joints between die-cast ADC12 aluminium alloy (Al, 11.53%Si, 2.02%Cu) and S45C carbon steel (0.46%C, 0.64%Mn, 0.12%Cu) were fabricated by friction stir welding and their static strength and fatigue properties were investigated. Weldi…

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…

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 …

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…

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…

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 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 …