TWI Digital Library

The influence of the process parameters on the microstructure, mechanical properties and corrosion of friction stir welded aluminium alloy 2024-T3 was investigated. Sheets of 1.6 and 4 mm thickness were welded using rotational speeds of 800-2400 rpm…

In battery cell assembly, tab-to-busbar joint connections are usually done by welding incompatible metals such as Ni and Al. Micro friction stir welding is becoming increasingly popular as a joining method due to its solid-state nature. Nonetheless,…

Friction stir welding (FSW) experiments were conducted on X52 and X60 pipeline steel specimens (outer diameter 324 mm, wall thickness 6.35 mm) and weldment integrity was evaluated by metallography, NDE and mechanical properties characterisation. Wel…

A friction stir spot welding process was employed to fabricate dissimilar joints between 6016 aluminium alloy (Al, 1-1.5%Si, 0.25-0.6%Mg) and galvanised HSLA 280 phosphorus-hardened cold rolled steel (0.08%C, 1.3%Mn, 0.1%Ti, 0.08%Al, 0.09%P), and th…

With regard to the development of friction stir welding (FSW) processes for joining large thin walled 3D structures in aircraft fuselage applications, an investigation is presented into the "LuFo IV" machine concept, incorporating clamping, position…

Friction stir spot welding (FSSW) experiments were undertaken on sheet specimens (thickness 1.3 mm) of AZ31 magnesium alloy (Mg, 3%Al, 1%Zn) and the effects of process conditions and workpiece surface condition on the macrostructure, microtexture an…

Two common approaches to describe kinematics in simulations of the friction stir welding (FSW) process, the Lagrangian representation and the Eulerian representation, were compared using "ABAQUS/Explicit" and "FLUENT" software programs, and the infl…

Friction stir welding (FSW) of 2219-T6 aluminium alloys (Al, 6.48%Cu) was undertaken with the assistance of micro-plasma arc preheating, and welding efficiency as well as joint microstructure and mechanical properties were investigated. Longitudinal…

Friction stir spot welding (FSSW) experiments were conducted between AA 5052 aluminium alloy and an SP-270C low carbon steel under various process conditions (tool rotation speed 1000-5000 rpm, plunge depth 0.1-0.7 mm), and the microstructure and me…

The material flow of aluminium alloy and steel during dissimilar friction stir spot welding was visualised using zinc tracers and the surface temperature of the flat-tipped tool during stirring was measured by telemetry. Welds were produced in AA505…

The swept frequency friction stir spot welding technique was employed to fabricate lap joints in 6061 aluminium alloy workpieces and the influence of process parameters on mechanical properties was investigated. Welding experiments were conducted us…

This study explores the microstructural evolution of AA6060 builds that were fabricated via the recently developed Friction Screw Extrusion Additive Manufacturing (FSEAM) approach, and the role of a subsequent post-manufacturing ageing heat treatmen…

In this study, RFSSW of similar 5052-0 and 6061-T6 aluminum alloys with various thickness from 1.0 mm to 3.0 mm were performed by using cemented carbide tools. Microstructural features and mechanical properties of the joints produced with optimized …

In relation to the application of ferritic/martensitic steels as cladding and duct materials in advanced nuclear reactors, an investigation is presented into the friction stir welding of P91 high alloy steel (0.11%C, 0.45%Mn, 8.41%Cr, 0.96%Mo) plate…

Numerical modelling and experimental measurements were undertaken to investigate the extension and microstructure of the HAZ during friction stir welding (FSW) of 7075 aluminium alloy (Al, 5.86%Zn, 2.37%Mg, 1.91%Cu) thin sheets (thickness 1.2 mm). W…

Process force and discontinuity models were derived to estimate the forces observed in friction stir welding (FSW) in order to develop a method of detecting discontinuities during FSW using physics-based process modelling. FSW welded joints with and…

Single run friction stir welding (FSW) experiments were undertaken on plate specimens (thickness 6 mm) of 7A60-T6 aluminium alloys (Al, 8.89%Zn, 2.74%Mg, 2.26%Cu) and the relationship between process parameters, microstructure and mechanical propert…

Use of friction stir welding (FSW) to replace mechanical fastening in fabrication of an aircraft component in the ROCT Project (Rib One with Crux and Tees) is described. Design is shown of the part, which was assembled using four butt welds from wro…

Dissimilar joints between 2017A-T451 (Al, 4.14%Cu, 0.72%Mg, 0.68%Si) and AlSi9Mg (Al, 8.6%Si, 0.64%Fe, 0.34%Mn, 0.31%Mg) aluminium alloys were fabricated by a friction stir welding process featuring different rates of rotation of the pin and shoulde…

With regard to the occurrence of coarse alpha-Al dendrites, eutectic phase, shrinkage porosity and other defects in cast aluminium alloys, an investigation was undertaken into the influence of different combinations of friction stir processing (FSP)…