TWI Digital Library

Dissimilar lap joints between AlSi10MgMn aluminium alloy sheets (thickness 3 mm) and Al-Si coated Usibor 1500 22MnB5 hot stamped boron steel sheets (thickness 1.8 mm) were fabricated by friction stir spot welding (FSSW) under different processing co…

Carbon nanotube reinforced AA 6063 aluminium alloy (Al, 0.65%Mg, 0.34%Si) metal matrix composite (MMC) sheets (thickness 1.8 mm) were joined by friction stir welding (FSW) and experimental studies were undertaken to examine the MMC weldability as we…

A numerical and experimental study was undertaken to investigate the mechanism of swing friction stir spot welding (FSSW) and the effects of swing length and weld direction on the joint strength. Coupons were taken from a commercial A6022-T4 alumini…

Friction stir linear welding and friction stir spot welding techniques were employed to fabricate robust and reliable welded joints for automotive front end substructure applications between AA6022-T4 aluminium alloy and AM60B magnesium alloy sheets…

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%…

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…

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…

Two abutting plates (thickness 6 mm) of Al 6061-T6 and cold rolled AISI 1018 mild steel were friction stir welded along the butt joint with the steel and aluminium, respectively, on advancing and retreating sides, and the relationship between proces…

A review is presented of process development work undertaken with regard to a machine concept assessment and the realisation of a fully 3D-capable 5-axis parallel kinematic friction stir welding machine, a so-called pentapod, suitable for large and …

Friction stir processing (FSP) experiments were undertaken to modify the microstructure of Ti-6%Al-4%V parent metal specimens, in both alpha/beta and beta processed conditions, and TIG weld overlays deposited onto Ti, 6%Al, 4%V alloy using matching …

An investigation is presented into the fatigue characteristics of friction stir welded (FSW) lap joints made from artificially aged Al alloy 6082 (Al, 0.6-1.2%Mg, 0.7-1.3%Si) using a tool based on the "Triflute" concept with either convex or concave…

A 16-run screening design of experiments (DOE) was conducted to analyse the effects of nine factors during friction stir welding on process forces, temperatures and shoulder depth. The factors were spindle speed, feed rate, plunge depth, pin length,…

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…

With regard to the dependence of welded joint properties on tool probe shape during friction stir welding (FSW) of dissimilar butt joints between aluminium and steel, an investigation was undertaken into the interface formation mechanism by conducti…

An investigation is presented into the effect of frictional heating on joint behaviour during friction stir welding (FSW) between aluminium alloy 6063 and mild steel S45C, the cross-section microstructure of the weld interface, and the welding mecha…

The friction stir welding of dissimilar aluminium alloys for the production of aircraft structural components was investigated. Welds were made between alloys 7040 and 7449 pre-aged to obtain a defined temper after post-weld ageing. Alloy 7040 was a…

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…

The relationship between microstructure and properties, and the influence of microstructure on the fracture toughness of friction stir welded aluminium alloys with weld zone strength undermatching were investigated. Welds were made in 5005-H14, 2024…

A friction stir welding (FSW) process map for AA 7075-T6 aluminium alloy (Al, 5.1-6.1%Zn, 2.1-2.9%Mg, 1.2-2%Cu) was determined using combined NDT techniques such as visual inspection, dye penetrant testing, X-ray radiography and ultrasonic testing a…