TWI Digital Library

The main factors to be considered in the automation and robotisation of friction stir welding (FSW) and the production of one-, two- and three-dimensional welds were identified. A FSW robotic cell was developed and force control algorithms were defi…

A fully Lagrangian smoothed particle hydrodynamics method was employed to simulate the bobbin tool friction stir welding process for aluminium alloys in order to evaluate tool torque and forces as well as material flow for different advancing speeds…

Some numerical and experimental results are presented to illustrate the ability of the SignaStir laser ultrasonic testing system to monitor the occurrence of voids, cavities and lack of root penetration defects during friction stir welding (FSW). A …

The corrosion behaviors of friction stir welded (FSW) joint of 7075 aluminum alloy with and without shot peening treatment (SPT) were investigated by method of acid salt spray. The macroscopical and microscopical corrosion features were observed by …

A device was designed and manufactured to facilitate accurate monitoring of forces, torque and tool temperature during friction stir welding (FSW) and for use as a weld quality indicator in relation to issues such as tool wear, lack of tool penetrat…

Following a summary of the current applications for friction stir welding at Boeing, the Brotje Automation FSW system is introduced. Presentation slides give notes on complex contour FSW in a large work envelope, the characteristics of a robust prod…

Dissimilar joints between AA 6061 aluminium alloy (Al, 0.91%Mg, 0.52%Si, 0.6%Fe) sheets (thickness 2 mm) and zinc-coated HIF-GA (high strength interstitial-free galvannealed) steel (0.002%C, 0.09%Si, 0.47%Mn) sheets (thickness 1 mm) were fabricated …

The large load friction stir spot welding (LL-FSSW) technique was applied to a low carbon steel sheet in order to achieve lap joints at a low temperature, and the microstructure and hardness of the joints were investigated. The composition of the gr…

In the last fifteen years, friction stir welding has developed from a laboratory curiosity to an important fabrication technique for lightweight, lower softening temperature alloys. Industrial implementation of joining magnesium has been limited alm…

A modified Gleeble hot torsion test was used to simulate the stir zone microstructures in types 304L and 310 stainless steels obtained during friction stir welding (FSW). A Gleeble 3800 with a torsion mobile conversion unit was used to perform the t…

A simultaneous double sided corner Ad-Stir fillet stationary shoulder friction stir welding (SSFSW) process was developed for LNG (liquefied natural gas) storage tank construction. The microstructure and mechanical properties of welded joints were i…

The non-destructive testing (NDT) aspects of the Qualistir project for the on-line quality control of friction stir welding in aluminium are described. Definitions are given for the following defects: voids, wormholes, lack of penetration, faying su…

The development of three-dimensional column-type friction stir welding (FSW) equipment for robotic FSW of joints with complex shapes is described. The process requires a large force and precision control for tool penetration. The specification of th…

The influence of pores and residual stresses on fatigue crack propagation was studied for friction stir welded joints in aluminium alloys 2024-T3 and 6013-T6 of thickness 4 mm. Good welds and pore-containing welds were produced using tools with and …

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…

Tensile testing was used to characterise and compare the fracture locations and their influencing factors for a number of friction stir welded aluminium materials (AA-1050, AA-2017, AA-6061). Friction stir welding was carried out on sheets of thickn…

A combined analytical and experimental study was carried out to determine power, heat input, tool shoulder temperature and process efficiency for the FSW of aluminium alloys, carbon steels and titanium alloys and to compare heat input with that for …

Friction stir welding (FSW) was used to form lap joints in two aluminium alloys: A5182 without heat treatment and AlMg0.5Si1 sheet in T4 condition. Sheet thicknesses of 1 and 2 mm were used. The effects of tool rotation direction were assessed. The …

Lap joints between 2 mm aluminium alloy sheet in 2024-T3 (Al, 4.4%Cu, 1.5%Mg, 0.6%Mn) and 7075-T6 (Al, 1.6%Cu, 2.5%Mg, 0.23%Cr, 5.6%Zn) were prepared and evaluated. The welds were produced using a range of welding and tool speeds, with a non-threade…

The mechanical properties of the parent metals and friction stir welded joints in aluminium alloy 6 mm plate 2014A, 7075 and 5083 are summarised. CTOD and J fracture toughness results are reported for the parent metal and up to five different region…