TWI Digital Library

Orientation imaging microscopy was employed to characterise the stir zone microstructure in relation to the defect formation tendency and evaluate the peak temperature at different locations in friction stir welded Ti-6%Al-4%V specimens. Welded join…

A model which considers heat transfer to both tool and workpiece was developed to predict temperature distributions for the friction stir welding (FSW) process. The model assumes a cylindrical pin generating heat at the interface by friction, and th…

Experiments were conducted to compare heat input and weld hardness in friction stir welding (FSW) and MIG welding of aluminium alloy. Material A-6N01-T5 (Al, 0.8%Mg, 0.6%Si) of thickness 4 mm was used. The heat inputs were measured by calorimetry. H…

Alternative friction stir welding tool shoulder materials to improve welding speed and quality were evaluated. The materials, which were compared with tool steel using a tool designed for exchangeable shoulder inserts, were: nitrided tool steel, Inc…

A real-time wireless temperature measurement system was developed to facilitate improved temperature measurement at the tool-workpiece interface and a closed-loop control system for friction stir welding (FSW) that maintains weld quality under vario…

Experimental measurements and thermal modelling were used to determine the transient heat loss into friction stir welding tools and so calculate the welding efficiency. Energy inputs were determined from force and torque measurements made whilst per…

Multi-material structure is effective way to achieve lightening of vehicles for reduction of CO2 emission. Thus, carbon fiber reinforced thermo-plastic (CFRTP) and aluminum alloy (Al) are useful materials for lightening of vehicles. For fabrication …

A non weldable to weldable (N2W) methodology is presented in which friction stir welding (FSW) is used to join a non weldable (but highly wear resistant) material to a weldable material (e.g. a steel insert positioned within the wear resistant mater…

Experimental methods were developed to track material flow and mixing during the friction stir welding (FSW) process. Experiments were conducted with butt joints of 6.35 mm (0.25 in) thickness 7050-T7451 aluminium alloy plates. The FSW tool was H13 …

Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process dev…

Friction stir welding (FSW) has been used to weld aluminum alloys such as 7075 to 7075, which is considered not weldable by most other methods. In this application FSW was used to join two dissimilar aluminum alloys 7075 and 6N pure copper in a lap …

An extensive study of friction stir welding (FSW) of HSLA-65 steel plate (thickness 6 mm) was undertaken, incorporating defect-free friction stir butt welding at a travel speed of 3.4 mm/s, the achievement of low/no distortion FSW by employing appro…

Variations in microstructure in friction stir welds in AA 7449 (Al, 2.2%Mg, 8.2%Zn, 1.7%Cu, 0.12%Si, 0.15%Fe, 0.2%Mn, 0.05%Cr, 0.25 T plus Zr) in the initially overaged (T7) condition were studied. Isothermal heat treatments were conducted at 350 an…

Sleeve plunge friction spot welding was employed to join AA5042 aluminium alloys under various process conditions and the microstructure and the mechanical properties of the welded joints were investigated. Welding was performed using a three-piece …

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 …

A refill friction stir spot welding technique was employed to fabricate joints in AA 2014 aluminium alloy (Al, 3.51%Cu, 0.7%Mn) sheets (thickness 2 mm) and the effect of tool rotational speed on microstructure and mechanical properties was investiga…

A methodology incorporating friction stir processing (for plasticising) and friction stir welding (for joining components) was developed to fabricate T-shaped copper conductor rails. Experiments were undertaken on copper plate specimens (thickness 8…

AZ31 magnesium alloy sheets (thickness 3 mm) were joined by TIG welding and the effect of two run rapid cooling friction stir processing (RC-FSP) on welded joint microstructure and mechanical properties was investigated. TIG welding was undertaken a…

Kahn notched tear tests and fractography were employed to investigate variations in toughness and fracture mode across the weld zones in friction stir welded AA 7449 plates (thickness 40 mm) in the TAF (temper for age-forming) condition. Welding was…

Numerical simulations and experimental measurements were undertaken to study the temperature fields developed during friction stir welding (FSW) of AW 5083 (Al, 4-4.9%Mg, 0.25%Mn) alloy plates (thickness 10 mm). Welding was conducted at a rotational…