TWI Digital Library

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…

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 …

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…

The feasibility of using friction stir welding (FSW) in the construction of an aircraft central wing box from butt-welded extrusions was evaluated. An FSW procedure for welding 7055 T77511 and 7349 T6511 10 mm thickness extrusions was developed by T…

The design, construction and use of a purpose-built friction stir welding machine for the welding of 15.9 mm (0.625 in) thickness, 1.88 m (74 in) long aluminium alloy 6061-T6 plate and extruded sections to form the side panels of a laser system is d…

A softening model was constructed for friction stir welding (FSW) of 2xxx series aluminium alloys and was combined with previously derived thermal cycle modelling work. A thermal model of energy input and heat conduction was used to calculate therma…

A non weldable to weldable (N2W) methodology is presented in which friction stir welding (FSW) is used to join a non weldable (but highly wear resistant) material to a weldable material (e.g. a steel insert positioned within the wear resistant mater…

Friction stir welding (FSW) has been used to weld aluminum alloys such as 7075 to 7075, which is considered not weldable by most other methods. In this application FSW was used to join two dissimilar aluminum alloys 7075 and 6N pure copper in a lap …

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…

An extensive study of friction stir welding (FSW) of HSLA-65 steel plate (thickness 6 mm) was undertaken, incorporating defect-free friction stir butt welding at a travel speed of 3.4 mm/s, the achievement of low/no distortion FSW by employing appro…

Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process dev…

Variations in microstructure in friction stir welds in AA 7449 (Al, 2.2%Mg, 8.2%Zn, 1.7%Cu, 0.12%Si, 0.15%Fe, 0.2%Mn, 0.05%Cr, 0.25 T plus Zr) in the initially overaged (T7) condition were studied. Isothermal heat treatments were conducted at 350 an…

Experimental measurements and thermal modelling were used to determine the transient heat loss into friction stir welding tools and so calculate the welding efficiency. Energy inputs were determined from force and torque measurements made whilst per…

Experimental methods were developed to track material flow and mixing during the friction stir welding (FSW) process. Experiments were conducted with butt joints of 6.35 mm (0.25 in) thickness 7050-T7451 aluminium alloy plates. The FSW tool was H13 …

Alternative friction stir welding tool shoulder materials to improve welding speed and quality were evaluated. The materials, which were compared with tool steel using a tool designed for exchangeable shoulder inserts, were: nitrided tool steel, Inc…

With regard to the use of copper canisters for the storage of spent nuclear fuel, an investigation is presented into a cascade controller to maintain probe temperature and to control power input and tool depth during friction stir welding procedures…

Numerical simulations and experimental measurements were undertaken to study the temperature fields developed during friction stir welding (FSW) of AW 5083 (Al, 4-4.9%Mg, 0.25%Mn) alloy plates (thickness 10 mm). Welding was conducted at a rotational…

Dissimilar butt joints between aluminium alloys and steel or an AZ91 magnesium alloy (Mg, 9.39%Al, 0.85%Zn) were fabricated by ultrasound enhanced friction stir welding (USE-FSW) and their microstructure, mechanical and corrosion properties were inv…