TWI Digital Library

The use of a full-length welding process to repair defective friction stir welded (FSW) butt joints in aerospace aluminium alloys was evaluated. Lack of penetration, offset and tunnel defects were investigated in AA6156-T6, AA2198-T8 and AA2024-T3 a…

Friction stir welding was employed to fabricate bead-on-plate welds on AA 6063 aluminium alloy sheets (thickness 5 mm) and dissimilar joints between AA 6063 and S45C carbon steel plates (thickness 6 mm), and the influence of weld shape on microstruc…

The microstructure, hardness, indentation profile, tensile strength, fracture cracking and grain boundaries of friction stir overlap welds in 2124 aerospace aluminium alloy were investigated. Welds were made in EN AW-2124 heat-treatable wrought AlCu…

An indirect temperature measurement system was developed based on the acquisition of torque and process forces during friction stir welding (FSW) and a mathematical model incorporating a grey box approach was formulated to determine the correlation …

With regard to the application of friction stir welding (FSW) for the butt weld joining of aluminium alloy extrusions into large panels for ship decks and railway carriages, an investigation is presented into the employment of laser ultrasonic testi…

Haynes Alloy 282 (Ni, 19.45%Cr, 10.28%Co, 8.55%Mo) was deposited onto Inconel 600 substrates (Ni, 16.69%Cr, 9.36%Fe) using a cold-wire TIG process, subjected to additive friction stir processing (AFSP) to create gamma-strengthened surface layers, an…

The influence of weld length on pin breakage during friction stir welding (FSW) of aluminium alloy was investigated. Tool geometry, microstructure, pin diameter and the occurrence of cracking were studied during welding. Welded joints were made in 7…

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…

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…

In relation to the industrialisation of the friction stir welding process to facilitate qualification of welding machines for different applications, a methodology is presented based on the interactions between tool, workpiece and material. Issues d…

A report is presented into the "RoboFSW" project, intended to qualify a high payload articulated arm robot for friction stir welding (FSW); hardware modification and control system integration are described and 3D FSW capability is reported for circ…

A numerical and experimental study was undertaken to investigate the mechanism of swing friction stir spot welding (FSSW) and the effects of swing length and weld direction on the joint strength. Coupons were taken from a commercial A6022-T4 alumini…

Two abutting plates (thickness 6 mm) of Al 6061-T6 and cold rolled AISI 1018 mild steel were friction stir welded along the butt joint with the steel and aluminium, respectively, on advancing and retreating sides, and the relationship between proces…

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 …

Dissimilar joints between 6061-T4 aluminium alloy and S45C steel sheets (thickness 1.6 mm and 1 mm, respectively) were fabricated by the friction stir clinching technique using two types of tools and their mechanical properties and failure modes wer…

Friction stir linear welding and friction stir spot welding techniques were employed to fabricate robust and reliable welded joints for automotive front end substructure applications between AA6022-T4 aluminium alloy and AM60B magnesium alloy sheets…

The surface quality, microstructure and crystallographic texture were investigated as a function of traverse speed for friction stir welds of Ti-6Al-4V, produced using static shoulder tools consisting of a tungsten-rhenium probe and a silicon nitrid…

Based on the hypothesis that uniform friction stir weld quality can be produced by maintaining a constant weld zone temperature, an investigation was conducted to develop a feedback strategy and a closed-loop control algorithm to maintain constant t…

With regard to the need for in-process subsurface defect monitoring during friction stir welding (FSW) of aluminium alloys, an investigation is presented into a real-time force measurement system of process output to sense defect formation. Issues d…

An experimental investigation was made on the effect of processing variables and tool material on the microstructure of friction stir welded (FSW) 6 mm thick HSLA-65 steel plate, with the aim of optimising the process variables for enhanced mechanic…