TWI

The concept and theoretical principles of friction flow welding are presented. Numerical simulation using 'Deform-3D' software was used to compared and optimise the process. The applicability of friction flow welding to different aluminium alloys wa…

Friction stir welding (FSW) using a milling machine was employed to join AA-6063-T6 alloy (Al, 0.51%Mg, 0.42%Si) pipes (diameter 110 mm, thickness 5 mm) with the aim of eliminating ploughing problems, and weld zone microstructures were studied as a …

The design of a polycrystalline cubic boron nitride friction stir welding tool, tool holder and machine for use with high melting temperature materials is described. A polycrystalline cubic boron nitride truncated cone tool tip, capable of working a…

A 3D fully coupled computational fluid dynamics model was established to investigate the heat generation and material flow during friction stir welding, and the measured tool torque and axial force were used to characterise the contact conditions (f…

Thermomechanical modelling of the friction stir butt welding process in AA 5083-H18 aluminium alloys was undertaken using a CFD (computational fluid dynamics) code to describe the steady state, and simulated temperature profiles were compared with t…

Friction stir processing (FSP) experiments were undertaken on annealed AISI 420 stainless steel plates (thickness 6 mm) in order to compare three methods for assessing tool wear. The investigations incorporated two tool compositions (WC-Co or polycr…

The degradation mechanisms of friction stir welding (FSW) tools made of three tungsten alloys were investigated. Tools were made from 99%W-1%La2O3, 75%W-25%Re and 70%W-20%Re-10%HfC. These were used to make friction stir welds in high strength steel …

The hybrid component of the combination magnesium’s lightness and aluminum’s formability should be useful for energy saving. The welding of dissimilar metallic materials is difficult for their difference in melting temperatures and the formation of …

A man-machine interface for friction stir welding (FSW) was proposed that allows a human operator to augment a traditional control system by monitoring and continuously adjusting the parameters of an established welding programme, and hardware and s…

A tool made from a Co-based alloy strengthened by precipitation of an intermetallic Co3(Al,W) gamma phase with an L12 structure was developed for friction stir welding of high-softening-temperature materials, such as a 0.45%C steel, and the tool wea…

4th International Symposium, 14-16 May 2003, Session 5A: Aerospace 2, Paper 01

The use of friction stir welding for the repair of cracks in aluminium alloy 2024 aircraft wing skin structures, and the repair fatigue life were investigated. An artificial crack, 42 mm in length, in a flat section 2024-T351 alloy of 3.2 mm thickne…

A report is presented into the friction stir welding (FSW) fabrication of an aluminium deck for a pedestrian bridge over the Petite Decharge river (Alma, Quebec, Canada), incorporating the design and manufacturing of extrusions, FSW tools and a syst…

An approach to welded joint inspection incorporating in situ characterisation of weld quality was developed to facilitate the detection of discontinuities (e.g. voids and volume defects) during friction stir welding (FSW). FSW experiments were perfo…

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…

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…

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…

Finite element models of the friction stir welding of aluminium alloys are reviewed and the results compared with experimental measurements. Contact between the pin and the workpiece is considered in two ways: frictional contact; or assuming the mat…

A friction stir spot welding process was employed to fabricate dissimilar joints between 6016 aluminium alloy (Al, 1-1.5%Si, 0.25-0.6%Mg) and galvanised HSLA 280 phosphorus-hardened cold rolled steel (0.08%C, 1.3%Mn, 0.1%Ti, 0.08%Al, 0.09%P), and th…

An accurate temperature feedback strategy and closed-loop feedback control system for temperature have been developed for friction stir welding. A wireless data acquisition system was constructed to measure temperatures at the tool-workpiece interfa…