TWI Digital Library

The friction stir welding of copper for the production of spent nuclear fuel storage disposal canisters was investigated. Initial trials were conducted on UNS-C10100 plate of 10 mm thickness. The high temperatures required the use of a sintered tung…

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…

Two techniques developed on TWI's "RoboStir" system, robotic floating-bobbin friction stir welding (RFBFSW) and robotic stationary shoulder friction stir welding (RSSFSW), are described and some results from welding trials are presented. The RFBFSW …

A friction melt bonding process was employed to fabricate dissimilar lap joints between ultralow carbon (0.01%C, 0.14%Mn) or dual-phase DP600 (0.08%C, 1.51%Mn, 0.35%Cr, 0.06%Mo) steel grades and 1050, 2024 or 6061 aluminium alloys and the microstruc…

The stationary shoulder technique was applied to the self reacting pin tool (SRPT) for friction stir welding (FSW) of high quality aluminium alloy railway car body structures in order to enhance the appearance of no coating side structures construct…

Controlled force monitored plug-in tests were undertaken to investigate the influence of rotational speed and to analyse flow regimes during friction stir welding (FSW) of different aluminium alloys. Experimental specimens comprised sheets (thicknes…

A thermal model with a thermo pseudo mechanical (TPM) heat source was employed to investigate the influence of process parameters (rotational speed, feed rate and tool geometry) on the temperature profile at the interface of dissimilar metal lap joi…

AA 2219 aluminium alloy sheets (thickness 2.5 mm) were joined by friction stir welding (FSW) and an investigation was undertaken into the relationship between joint mechanical properties, the torque generated by the spindle motor and process variabl…

A kinematic approach is presented for modelling the friction stir welding process and the relationship between tool geometry and process parameters. The model was used to describe the correlation between features of the weld nugget, process paramete…

Vertical and angular truss extrusions made from 6082-T6 aluminium alloy (Al, 0.7-0.74%Mg, 1.04-1.14%Si, 0.53-0.54%Mn) were friction stir welded in a half-overlap configuration to fabricate panels for marine applications and their fatigue performance…

A cantilever type rotary bending fatigue testing machine with high speed loading capability was employed to investigate the high cycle fatigue properties of the stir zone, thermomechanically affected zone and HAZ in friction stir welded joints of va…

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…

Friction stir welding (FSW) experiments were undertaken on sheet specimens (thickness 5 mm) of 5454-H111 aluminium alloys and the relationships between process forces, spindle power and tool geometry were investigated. Twelve FSW tools with specifie…

A friction stir welding (FSW) methodology incorporating laser tracking and constant force control technologies was developed in order to fabricate large, thin-walled aircraft floor structures. The material chosen for study comprised sheet specimens …

The bobbin tool or self-reacting tool variant of the friction stir welding process was investigated on butt joints of various 2000 series aluminium alloys for aircraft fuselage applications; welding feasibility tests were conducted in pin length con…

With regard to the development of dissimilar aluminium-steel joint fabrication for automotive applications such as body-in-white, an investigation incorporating experiment and numerical simulation was undertaken to examine the dissimilar friction st…