TWI

Technology improvements and process innovations in respect of friction stir welding (FSW) of high temperature materials are reviewed, welding process conditions and mechanical properties of completed welds for various alloys using polycrystalline cu…

An investigation is presented into the processing window for friction stir welding (FSW) of Formall 545 (equivalent to AA-5083) to age-hardened AA-6082 aluminium alloys with regard to tool rotation and traverse speeds, and into an evaluation of a nu…

An experimental study was conducted to measure the torque of friction stir welded cast aluminium A356 (Al, 7%Si, 0.3%Mg) over a range of travel and rotational speeds. Plates of 6.35 mm thickness were FSW using travel speeds and rotational speeds ran…

A brief review is presented of the state of development of polycrystalline cubic boron nitride (PCBN) tool materials for friction stir welding (FSW) of high-temperature materials (high alloy steels and Ni based alloys) with respect to weld penetrati…

As part of a project to develop a physical-mathematical model and software for thermal simulation of the friction stir welding (FSW) process, an initial version "FricSim2.2" was created and verified, using the software tool "SpotFSW" to convert the …

Butt joints were fabricated in AA 2219-T87 aluminium alloy panels (thickness 6.35 mm) by friction stir welding (FSW), and force data collected during welding were analysed using an unsupervised matched filter technique to classify weldment segments …

An instrumented constrained Charpy test was used to measure the fracture toughness of friction stir welded joints produced using several designs of welding tool in sheet aluminium alloys 6082 (4.7 mm) and 7108 (3.2, 5.0 mm). This test constrained pl…

Friction stir welding (FSW) trials were carried out for thin HSLA-65 steel plate (6 mm thickness) to evaluate the potential benefits of using induction preheat. Other studies including tool design and multi-run welding are also evaluated as methods …

With regard to the fabrication of hollow structures by the inversion friction stir welding (IV-FSW) technique, welded joints were fabricated in A-1050 and A-6061 aluminium alloy and SPCC steel sheets (thickness 2 mm) by IV-FSW and their surface appe…

In order to study the relationship between material flow and the development of highly variant process forces during friction stir welding (FSW), a high sampling rate triaxial force measurement device and a high speed camera were employed to monitor…

Lap joints were fabricated in AA 7075-T6 aluminium alloy sheets (thickness 2 mm) using an ESAB "Rosio" friction stir welding (FSW) robot and the effect tool of side-tilt angle on welded joint tensile strength was investigated. A "CounterStir" FSW to…

Dissimilar welded joints between AW 6061-T6 aluminium alloy (Al, 0.93%Mg, 0.59%Si, 0.5%Fe) and AZ31B-H24 magnesium alloy (Mg, 2.55%Al, 0.79%Zn) were fabricated by friction stir welding and the influence of process parameters on their microstructure …

The bobbin tool or self-reacting tool variant of the friction stir welding process was investigated on butt joints of various 2000 series aluminium alloys for aircraft fuselage applications; welding feasibility tests were conducted in pin length con…

Friction stir welding (FSW) was investigated in aluminium alloys used in aircraft structures. Extruded shapes in alloys 2024 (Al, 4.96%Cu), 7475 (Al, 5.96%Zn, 2.57%Mg, 1.62%Cu) and 7050 (Al, 6.29%Zn, 2.36%Mg, 2.00%Cu) were welded; welds were evaluat…

An investigation is presented into the development of a flexible 3D friction stir welding (FSW) process capacity incorporating a rail mounted industrial robot to facilitate high production rate repair of aluminium cathodes for electro refining opera…

An integrated modelling approach, incorporating coupled process, material response and material performance models, was developed and implemented for use in friction stir welding (FSW) of aerospace structures. The process model employed was a dynami…

Friction stir processing (FSP) was employed to fabricate oxide dispersion strengthened copper-based composite plates with a graded microstructure and evolving mechanical, thermal, electrical and wear properties along their thickness. Specimens compr…

An experimental investigation was undertaken to study the effects of different pin profiles (threaded conical, square, pentagon and hexagon) and the same process parameters on temperature distribution around the tool and resulting microstructure dur…

A friction stir spot welding (FSSW) process was employed to fabricate dissimilar joints between an AA 5754 aluminium alloy and an AZ31 magnesium alloy in a lap joint configuration using a Zn layer at the interface to suppress intermetallic formation…

WC, 12%Co cemented carbide layers were deposited onto M2 tool steel (0.8-0.88%C, 3.8-4.5%Cr, 4.7-5.2%Mo, 5.9-6.7%W, 1.7-2.1%V) substrates by HVOF spraying and the effect of subsequent friction stir processing (FSP) on bonding strength and cermet coa…