TWI Digital Library

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…

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…

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…

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 …

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 …

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…

Friction stir welds were produced from S460N and S355N steel alloys for several combinations of welding speed and rotational speed with the heat input ranging from 130 to 180 [J/mm]; or, from insufficient to excessive. The welds were characterised a…

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…

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…

A comparative study was undertaken of three different machine types, a modified high payload robot, a CNC milling machine and an ESAB "SuperStir" FSW machine, in terms of their capability for FSW of various aluminium alloys using identical process p…

Friction stir welding was employed to fabricate welded joints in AA 7475-T7351 aluminium alloy plates (thickness 6.35 mm) and the effect of kissing bond defects on fatigue life and other mechanical properties was investigated. Welded test specimens …

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…

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…

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 geometric feature, termed the "Wiper", was developed to improve the weld track surface finish produced by friction stir welding (FSW) and processing tools with scrolled shoulders, and experiments were undertaken to investigate the influence of "Wi…

With regard to the development of ausformed H13 tool steel for high strength friction stir welding (FSW) tools, an investigation was undertaken to explore methods to improve equal channel angle extrusion (ECAE) as the deformation step. Studies invol…

A Taguchi design of experiments approach was employed to investigate the effect of varying process parameters (rotational speed, welding time and plunge depth) on process data for refill friction stir spot welding of AA 6082-T6 aluminium alloys. The…

A fully integrated approach to facilitate optimisation of the friction stir welding (FSW) process was developed, incorporating a model for the FSW process, coupling material flow and thermal analysis, a model for precipitation evolution, a microstru…

An investigation is presented into the influence of tool flats, tool runout magnitude and relative tool runout orientation on the high speed forces acting transversely and longitudinally on the friction stir welding tool. Partial penetration bead-on…

Friction stir welding (FSW) was employed to fabricate butt joints in AW 5083 (Al, 4-4.9%Mg, 0.4-1%Mn) aluminium alloy plates (thickness 10 mm) and the influence of process parameters and tool geometry on the character and quality of welded joints wa…