TWI Digital Library

A presentation is made of a successful demonstration of the friction stir welding (FSW) of steel capabilities in a shipyard production facility, summarising the equipment, fixturing and tooling requirements. HSLA-65 steel panels (17m x 2.4m), 6mm th…

A friction stir welding (FSW) process based on the use of a self-reacting pin tool (SRPT) was developed for the joining of solid and hollow extrusions for aluminium railway car body structures; the mechanical properties of welded joints were investi…

Butt joints were fabricated in AA 2219-T87 aluminium alloy panels (thickness 6.35 mm) by friction stir welding (FSW), and force data collected during welding were analysed using an unsupervised matched filter technique to classify weldment segments …

Friction stir spot welding (FSSW) was employed to fabricate lap joints in hot extruded AZ31 magnesium alloy sheets (thickness 2 mm), and the effect of introducing nanostructured SiC particles (mean size 40 nm) on the microstructure and mechanical pr…

Quantification approaches applied to phase space data generated from friction stir welding aluminium alloys under varying process conditions are reported. A multi-step, micro-wormhole, non-destructive evaluation phase-spaced, (PS) algorithm that com…

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…

Friction stir welding (FSW) is discussed in manufacture of a sports car body made largely of aluminium alloy sheet with some components of cast aluminium or extruded aluminium, and the only steel used is the frame for the windscreen. Advantages are …

Nondestructive testing of friction stir welds is discussed. The ultrasonic testing of friction stir welded joints, advantages of phased array testing and test applications are presented briefly. The eddy current array testing technique is illustrate…

Fatigue tests were performed using lap-shear specimens of friction stir spot welded Al, 0.8%Mg, 1%Si alloys. Sheet specimens (thickness 2 mm) were subjected to PWHT of solution treatment and/or ageing. Weld zone microstructure was observed by SEM. F…

The joining of hot rolled aerospace quality AZ31B-H24 magnesium alloy (Mg, 2.5-3.5%Al, 0.7-1.3%Zn, 0.2-1.0%Mn) sheets (thickness 4.95 mm) was investigated using an MTS ISTIR friction stir welding (FSW) machine, the quality of the butt joints produce…

A brief review is presented of the state of development of polycrystalline cubic boron nitride (PCBN) tool materials for friction stir welding (FSW) of high-temperature materials (high alloy steels and Ni based alloys) with respect to weld penetrati…

Multirun friction stir processing (FSP) (12 mm depth over large surface area) was performed on NiAl bronze (Cu, 9.1%Al, 4.4%Ni, 3.9%Fe) thick plates (thickness 40 mm) using a rectangular spiral-out raster path, and longitudinal residual stresses wer…

An overview is presented of the twenty year history and technological developments relating to the application of friction stir welding (FSW) to aluminium alloy railway car body shells. Issues discussed include the history of railway car body shell …

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…

An experimental and numerical analysis of the wear of a polycrystalline boron nitride (PCBN) friction stir welding (FSW) tool is overviewed as presentation slides. Topics highlighted include: FSW plunge trials of EH46 shipbuilding steel at a plunge …

The integration of friction stir welding (FSW) into the manufacturing sequence of spinformed domes of aluminium alloys is presented in terms of its optimisation and the specific iterations required with the prior and follow-up procedures of the manu…

Friction stir spot welding (FSSW) was employed to fabricate dissimilar lap joints between a 6000 series aluminium alloy (Al, 1%Si, 0.5%Mg) in the T4 condition and SPCC mild steel (0.05%C, 0.01%Si, 0.14%Mn) without formation of intermetallic compound…

An investigation is presented into the use of a friction stir welding/forging process to fabricate tee and I-beam shapes with integral radial shaped fillets, the optimisation of process parameters for different alloys and shapes, and the results of …

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…