TWI Digital Library

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…

A two-run friction stir welding process was employed to fabricate butt joints in API 5L X80 pipeline steel (0.08%C, 1.86%Mn, 0.16%Cr, 0.01%Ni, 0.18%Mo, 0.03%V, 0.06%Nb) plates (thickness 12 mm) and fracture toughness was determined in the parent met…

With regard to the development of aluminium military vehicles, a report is presented into production level single run friction stir welding (FSW) process parameters for thick plate samples (thickness 12.7-40.6 mm) of 5083, 5059 and 2139 aluminium al…

Friction stir welding experiments were undertaken on commercial SPF (superplastic forming) AA 5083-H19 (Al, 4.43%Mg) and AA 2004 (Al, 6.05%Cu) aluminium alloys, and the effects of tool size, geometry and primary process variables on microstructure a…

Analytical modelling and experimental measurements were undertaken to investigate a dual-loop temperature control algorithm for friction stir processing, incorporating an inner loop to maintain constant power and an outer loop to set the power based…

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 microstructure of joints produced between dissimilar Al alloys by friction stir welding (FSW) was studied. FSW was performed for joining of 5083/6061 Al alloy workpieces of 5 mm thickness using a rotation speed of 1800 rpm and a welding speed of…

Three recently published finite element studies, modelling friction stir welding (FSW) of different aluminium alloys, were reproduced using ABAQUS software and the results were comparatively assessed. The models considered were as follows: heat tran…

The tensile and bend properties of friction stir welded butt joints in aluminium alloys 2024-T3, 6013-T6 and 7475-T76 were determined, including welds in 2024 and 7475 subjected to PWHT. The ultimate tensile strength, proof stress at 0.2% strain, an…

The origin of the lines of micrometre sized oxide particles observed in aluminium alloy friction stir welds was investigated. Butt and bead on plate welds were prepared using 6 mm plate of aluminium (99.999%Al and 99.5%Al) and aluminium alloy 6056 (…

The tensile and fatigue strength of friction stir welds were determined for aluminium alloy 6082 in various temper conditions. Plate of 5.8 mm thickness, in both T6 and T4 conditions, was welded using a tool speed of 1000 rev/min and a welding speed…

The effects of friction stir welding process parameters (tool rotation speed and travel speed) on defects and mechanical properties in welds in aluminium alloys were investigated. Microstructural, macrostructural and mechanical properties of the wel…

The feasibility of friction stir welding TIMETAL 21S beta titanium in the annealed condition was investigated. The composition of the alloy is Ti, 14-16%Mo, 2.4-3.2%Nb, 2.5-3.5%Al, 0.15-0.25%Si, max.0.4%Fe, 0.11-0.17%O, max.0.05%C, max.0.05%N, max.0…

In order to develop a method for microjoining by friction stir welding (FSW), micro-FSW trials were conducted on Mg alloy AZ31 (2.97%Al, 0.83%Zn) thin sheets (0.4 mm thickness), and the welding performance was assessed. The micro-FSW system incorpor…