TWI Digital Library

Based on a friction model incorporating the dynamic coupling between friction and material flow in heat transfer and fluid flow models, a computational fluid dynamics (CFD) methodology was employed to study material flow during friction stir welding…

Friction stir welding (FSW) experiments were undertaken on commercially pure Ti and Ti-6%Al-4%V plates (thickness 6 mm) by incorporating nickel foil markers of varying thicknesses to reduce forging load, enhance surface finish, eliminate void format…

The results of a programme to establish self reacting friction stir welding for thin gauge (less than 3 mm) aluminium alloy applications are reported divided into the five major phases: tool development; joint evaluation; strength optimisation; prot…

Modelling tools were developed to describe the relationships between process parameters, microstructural evolution and mechanical properties of the weld in friction stir welding (FSW). Experiments were conducted using aluminium alloy 6056. Initial t…

Work from two projects is described: "Qualistir" for the on-line quality control of friction stir welding in aluminium (by ultrasonic phased array examination of butt welded Al 7075); and a TWI feasibility study on inspection of Al 5083 butt and lap…

Computational fluid dynamics (CFD) methods were used to model the metal flow in the friction stir welding (FSW) process in order to optimise the pin profile to minimise the traversing force; welding experiments were carried out to validate the findi…

The influences of the thermal and mechanical stresses experienced during friction stir welding on the structure of coarse-grained aluminium alloy 2519-T87 were investigated. Plate of 25 mm thickness was welded at a speed of 1.5 mm/s, using a tool sp…

Friction stir welding (FSW) was investigated in aluminium alloys used in aircraft structures. Extruded shapes in alloys 2024 (Al, 4.96%Cu), 7475 (Al, 5.96%Zn, 2.57%Mg, 1.62%Cu) and 7050 (Al, 6.29%Zn, 2.36%Mg, 2.00%Cu) were welded; welds were evaluat…

A procedure has been developed for repairing welds made by friction stir welding (FSW) in cases where the tool breaks during welding. It involves the following stages: excavating the broken FSW tool, milling out a slot across the hole, machining an …

The quality of friction stir welds of butt joints (including the use of inserts to simulate compensation for poor fit up) between aluminium alloys 5083-H12 (Al, 4.6%Mg, 0.6%Mn, 0.3%Si) and 6082-T6 (Al, 0.7%Mg, 0.9%Si, 0.5%Mn), was evaluated. The wel…

The influence of friction stir welding on the microstructure and mechanical properties of aluminium alloy 6061 was investigated. Aluminium alloy 6061-T651 plate of 6.4 mm (0.25 in) thickness was friction stir welded and the joints characterised by o…

Friction stir welding (FSW) experiments on aluminium alloys were conducted using transparent PVC material to visualise dynamic material flow by direct observation, and the characteristics of two types of vortex were investigated. A single block of P…

A methodology is presented to define conical tool geometry and process parameters for friction stir welding (FSW) of thin plates. A calculation algorithm integrating a basic thermal model, tool geometry and process kinematics is proposed, the proces…

A friction stir welding (FSW) procedure, incorporating the use of different tool pins in combination with concave or scroll type shoulders, was employed to join various aluminium alloys; material flow was investigated with the aid of computer micro-…

With regard to the development of the stationary shoulder friction stir welding (FSW) technique as a long term loading joining process offering enhanced weld seam mechanical properties, an investigation is presented into coordinated material flow be…

Friction stir spot welding experiments were undertaken on AZ31 magnesium alloy (Mg, 3%Al, 1%Zn, 0.2%Mn) sheets (thickness 2 mm) in order to investigate the influence of a flame spray gun rapid preheating process on the microstructures and mechanical…

The microstructure, particle refinement and homogeneity of distribution of the refined particles during the friction stir processing (FSP) of AlSi alloys were investigated. A commercial hypo-eutectic LM24/A380 Al-8.9%Si gravity die cast alloy (26 mm…

The development of friction stir welding (FSW) technology for the Ariane 5 ME heavy launch vehicle project is illustrated with respect to the superior material properties of FSW within the parameter development and the manufacturing of circumferenti…

Dissimilar joints between an AA 5052 aluminium alloy sheet (thickness 1 mm) and an alumina plate (thickness 10 mm) were fabricated by friction stir spot welding (FSSW) and their microstructure and mechanical properties were investigated. Welding was…

Two types of WC-Co hard alloy tools (threaded and smooth) were used to friction stir weld an AC4A aluminium matrix composite (Al, 9%Si reinforced with 30 vol.% SiC particles) and the wear behaviour of the tools was investigated. Samples were butt we…