TWI

Friction stir welding tools of three different compositions (MS80, Q70 and Q60) of polycrystalline cubic boron nitride (PCBN) were tested to examine wear and fracture sensitivity. Three tools were made from each composition and were run for a total …

An experimental study was carried out to investigate the effect of welding conditions on weld macrostructure and the microstructure and mechanical properties of the nugget zone in welds in AA-7010 aluminium alloy made by friction stir welding (FSW).…

The material flows of aluminium and steel during friction stir welding were visualised in three dimensions using x-ray transmission radiographic real-time imaging. The movement of a miniature spherical tungsten tracer during welding was visualised u…

Torsion testing was carried out using a range of temperatures and strains to simulate the formation of nugget zone grain structures in friction stir welds of a typical aluminium alloy (7010) in order to investigate the formation mechanisms. Electron…

In relation to the challenges involved in temperature data acquisition and transmission associated with rotation of the friction stir welding (FSW) tool, an investigation is presented into a wireless temperature monitoring system based on thermocoup…

A real-time wireless temperature measurement system was developed to facilitate improved temperature measurement at the tool-workpiece interface and a closed-loop control system for friction stir welding (FSW) that maintains weld quality under vario…

Friction stir welding (FSW) experiments were performed on Al-based alloys prepared by direct-chill casting and continuous casting, and the influence of intermetallic particles and process parameters on onion ring zone morphology and microstructure w…

5083-O aluminium alloy sheets (thickness 3 mm) were butt welded using a gate-type friction stir welding (FSW) machine to investigate tolerance to deviations in butt-line/tool-travel line, gap spacing and tool roll angle, and the welded joints were e…

An investigation was undertaken to examine the effects of high welding speed and the use of thermal boundary conditions during friction stir welding (FSW) on the mechanical properties of AA 7050 aluminium alloy weldments. FSW experiments were perfor…

Friction stir spot welding experiments were conducted on dissimilar metal joints between AA5052 aluminium alloy and two kinds of steel (980 MPa high tensile strength steel and 270 MPa mild steel), and the microstructure and mechanical properties of …

Sleeve plunge friction spot welding was employed to join AA5042 aluminium alloys under various process conditions and the microstructure and the mechanical properties of the welded joints were investigated. Welding was performed using a three-piece …

The origin of the lines of micrometre sized oxide particles observed in aluminium alloy friction stir welds was investigated. Butt and bead on plate welds were prepared using 6 mm plate of aluminium (99.999%Al and 99.5%Al) and aluminium alloy 6056 (…

Thermomechanical and microstructural modelling were performed for the friction stir welding process, simulating the thermal diffusion during and after welding (in the cooling stage), and comparing the results with experimental data obtained for fric…

To better understand the heat generation, temperature distribution and material flow during friction stir welding (FSW), experiments, including some with a pin breaking technique, were undertaken on two aluminium alloys (5083-O (Al, 4.5%Mg) rolled p…

A numerical simulation is presented for the development and integration of a pin tool for friction stir welding (FSW) of aluminium alloys. The Triflute tool design was optimised. The macro- and microstructure of lap joints in A6N01 alloys were studi…

Friction stir lap diffusion welding was employed to fabricate dissimilar AA 6060 aluminium alloy/mild steel joints and mechanical testing and metallurgical examination of the weldments were undertaken to investigate the effect of microstructure form…

The use of friction stir welding, as an alternative to bolted or riveted joints, for the assembly of Airbus wings is discussed. Issues considered include: cost reduction, weight reduction, joint quality, and enhanced in-service performance. Potentia…

A review is presented of the progressive emergence of conceptual tools associated with friction stir welding (FSW) at the Marshall Space Flight Center, USA, from the discovery of the shear surface, wiping metal transfer and the invention of a kinema…

An investigation is presented into the use of temperature control in two friction stir welding (FSW) research projects: to understand the effect of backing plate conductivity on process parameters and to study the influence of active FSW tool coolin…

Friction stir welding was employed to fabricate welded joints in Ni-free 18%Cr, 2%Mo, 0.85%N austenitic steel sheets (thickness 3 mm) and the gradient characteristics of the microstructures and mechanical properties were investigated along transvers…