TWI Digital Library

Numerical simulations and experimental tests were undertaken to visualise material flow and to study the effect of the flow field on the mixing mechanism and particle break-up in friction stir welding of metal matrix composites. A 3D thermo-fluid mo…

The microstructure and corrosion properties of welded joints in Inconel 22 (Alloy 22 or NO6022) made by friction stir welding (FSW) were investigated. Bead-on-plate welds were produced in Alloy 22 (59.6%Ni, 13.43%Mo, 0.22%Cr, 3.29%W, 3.17%Fe, 0.84%C…

An investigation is presented into a methodology for simulating the entire friction stir welding (FSW) process using a hybrid mesh free method on a graphics processing unit (GPU) and its implementation for different FSW applications such as butt joi…

The repair of friction stir weld defects in aluminium alloy 6061-T6 3 mm thickness sheet (Al, 0.683%Mg, 0.564%Si) by friction stir welding was investigated using artificial defects. The defects were created using an unsuitable pin profile, whilst re…

The microstructure of a friction stir weld (of unknown welding parameters) in titanium alloy (Ti, 6%Al, 4%V) is described. The microstructure was studied using optical microscopy, SEM and TEM. The features of the parent material, HAZ and the thermom…

A process model for friction stir welding (FSW) of Al-Zn-Mg alloys, used to predict HAZ microstructure and hardness, is presented. Numerical solutions (using a finite difference approach) are developed for heat generation and heat flow. Microstructu…

The tensile and bend properties of friction stir welded butt joints in aluminium alloys 2024-T3, 6013-T6 and 7475-T76 were determined, including welds in 2024 and 7475 subjected to PWHT. The ultimate tensile strength, proof stress at 0.2% strain, an…

A computational fluid dynamics package, FLUENT, was used to model the viscous material flow during friction stir welding using two- and three-dimensional tool shapes. Two approaches were used to describe the viscosity. The first approach interpolate…

Several kinds of Co-based alloys with different mechanical properties (e.g. high temperature strength, hardness, wear resistance and gamma-solvus temperature) were designed for friction stir welding (FSW) tool applications by varying chemical compos…

Friction stir welding experiments were undertaken on 2195-T8 (Al, 3.99%Cu, 1.09%Li) alloy sheets (thickness 5 mm) and the weldability, microstructure and mechanical properties of the fabricated butt joints were investigated. Welding was performed us…

An experimental investigation was undertaken to examine how tool pin induced material flow and intermetallic growth conditions affect the formation of discontinuity during friction stir lap welding of dissimilar Al-Cu joints. The materials comprised…

A friction stir welding tool with a variable length probe (suitable for variable thickness joints, repairs and circumferential welding) was developed and evaluated for the welding of aluminium alloy 2195. Tapered sheet, of both increasing and decrea…

An indirect temperature measurement system was developed based on the acquisition of torque and process forces during friction stir welding (FSW) and a mathematical model incorporating a grey box approach was formulated to determine the correlation …

In relation to the industrialisation of the friction stir welding process to facilitate qualification of welding machines for different applications, a methodology is presented based on the interactions between tool, workpiece and material. Issues d…

Dissimilar joints between 6061-T4 aluminium alloy and S45C steel sheets (thickness 1.6 mm and 1 mm, respectively) were fabricated by the friction stir clinching technique using two types of tools and their mechanical properties and failure modes wer…

The fine scale precipitation in the nugget zone and in the HAZ of a weld in aluminium alloy AA-6082 (Al, 0.7%Mg, 0.5%Mn, 0.9%Si) of thickness 5-10 mm made by friction stir welding (FSW) was examined using transmission electron microscopy. The dissol…

Friction stir welding (FSW) was employed to fabricate a single overlap joint between sheet specimens (thickness 1.5 mm) of an AA 6181-T4 aluminium alloy and ZStE-340 high-strength steel, and weld phase composition, microstructure and mechanical prop…

The deformation behaviour and microstructural evolution of friction stir processed Zn, 22%Al rolled sheet (thickness 3 mm) were compared with those of the corresponding superplastic alloy. Friction stir processing was performed at a rotational speed…

Friction stir welding experiments between AA 6063 aluminium alloy and S45C carbon steel (thickness 6 mm) were performed, and the effects of heat input on the butt joint macrostructure (cavities formed at weld interface), hardness and plastic flow of…

The relationship between microstructure and properties in friction stir welding was studied. The effects of grain size, particle size and distribution, and dislocation density on weld strength in friction stir welds in work-hardenable Al alloy AA 52…