TWI

A computational fluid dynamics code ("CosmosFlow") was employed to evaluate the temperature distribution in materials during friction stir welding (FSW). Thermal simulations based on finite element models were undertaken to predict the optimum ratio…

Friction stir spot welding (FSSW) was performed on dual phase 800 high strength automotive steel (0.14%C, 0.23%Si, 1.52%Mn) to establish the effect of tool rotation speed (750-2400 rpm) for a number of weld cycles featuring different Z-axis plunge r…

Defect free welded joints were fabricated in 5083-O aluminium alloy (Al, 4.3%Mg, 0.65%Mn) plates (thickness 20 mm) by friction stir welding (FSW) and the influence of tool geometrical features on their microstructures and structure properties relati…

An investigation is presented into pore formation and grain growth in aluminium alloys during TIG welding after friction stir welding (FSW), for reasons of repair or fabrication, and into two methods to suppress these problems. The material studied …

The design, fabrication and evaluation of a portable friction stir welding (FSW) system for the in-situ field repair of aluminium structures to a depth of 6 mm is reported. The conceptual design of the FSW machine was produced using a dual-track app…

With regard to the application of friction stir welding (FSW) to the production of launcher tanks holding cryogenic liquids, an investigation was undertaken to establish a robust and industrialised FSW process for AA 2219 alloys in T87 and T851 cond…

Friction stir welding (FSW) studies were undertaken to join sheet and plate specimens of aluminium alloys in a butt joint configuration, and design of experiments methods were employed to optimise process parameters with respect to weldment quality …

In relation to the application of tailor welded blanks of aluminium alloys to the vehicle weight reduction process, an investigation is presented into the precipitation sequence in friction stir welded 6016 alloy sheets (thickness 2 mm) during a pai…

An experimental investigation is presented into the precipitation and hardening mechanism during FSW (friction stir welding) of Ni model alloys (Ni, 20%Cr, 2%Al, 2%Ti and Ni, 20%Cr, 3%Al, 3%Ti) in which Al and Ti contents were varied to control the …

An investigation was undertaken into the development and wear performance of friction stir welding (FSW) tools made from precipitation strengthened Ir-containing nickel-based superalloys (Ni, 25%Ir, 14%W, 4%Al) during FSW of Ti, 6%Al, 4%V alloys. Th…

Models to predict the precipitate and grain size evolution in AA7449 aluminium alloy friction stir welds are presented and compared with experimental data. Bead on plate welds on 3.2 mm thickness sheets of composition Al, 8.4%Zn, 2.1%Mg, 1.8%Cu were…

The influence of weld length on pin breakage during friction stir welding (FSW) of aluminium alloy was investigated. Tool geometry, microstructure, pin diameter and the occurrence of cracking were studied during welding. Welded joints were made in 7…

Evaluation of phased array ultrasonic inspection for the detection of typical friction stir weld defects is reported. Characteristics of friction stir welds with respect to inspectability are described. Phased array operation is outlined. A variety …

Friction stir welding of aluminium alloys suitable for railway and shipbuilding applications was investigated. Sheet of 4 mm thickness of alloys 6N01-T5 (Al, 0.7%Mg, 0.6%Si, 0.1%Cu) and 5083-H112 (Al, 4.7%Mg) were friction stir welded, and the joint…

A review is presented of the development of W, 25%Re friction stir welding (FSW) tool materials for application to steels and hard metals, such as titanium and nickel-based superalloys. Issues discussed include: the DUST (dual use science and techno…

Fatigue crack growth in friction stir welded (FSW) aluminium alloys 2024-T3 and 6013-T6 were predicted using two commercial software programs, ESACRACK and AFGROW in order to facilitate lifetime predictions of FSW aircraft structures. The following …

Numerical modelling and experimental measurements were undertaken to investigate the extension and microstructure of the HAZ during friction stir welding (FSW) of 7075 aluminium alloy (Al, 5.86%Zn, 2.37%Mg, 1.91%Cu) thin sheets (thickness 1.2 mm). W…

Process force and discontinuity models were derived to estimate the forces observed in friction stir welding (FSW) in order to develop a method of detecting discontinuities during FSW using physics-based process modelling. FSW welded joints with and…

Lap joints between 2 mm aluminium alloy sheet in 2024-T3 (Al, 4.4%Cu, 1.5%Mg, 0.6%Mn) and 7075-T6 (Al, 1.6%Cu, 2.5%Mg, 0.23%Cr, 5.6%Zn) were prepared and evaluated. The welds were produced using a range of welding and tool speeds, with a non-threade…

An analysis procedure was developed to relate the geometry and microstructure of lap configuration friction spot welds to the joints' mechanical behaviour. Using 2 mm thickness aluminium alloy AA 2024-T3 sheet as the basis for simulation, a three-di…