TWI Digital Library

Dissimilar joints between 6061-T4 aluminium alloy and S45C steel sheets (thickness 1.6 mm and 1 mm, respectively) were fabricated by the friction stir clinching technique using two types of tools and their mechanical properties and failure modes wer…

Friction stir linear welding and friction stir spot welding techniques were employed to fabricate robust and reliable welded joints for automotive front end substructure applications between AA6022-T4 aluminium alloy and AM60B magnesium alloy sheets…

The surface quality, microstructure and crystallographic texture were investigated as a function of traverse speed for friction stir welds of Ti-6Al-4V, produced using static shoulder tools consisting of a tungsten-rhenium probe and a silicon nitrid…

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 …

The feasibility of friction stir welding (FSW) for welding aluminium alloy 7020, used for the construction of light armoured fighting vehicles, was investigated and compared with MIG welding. Two joint configurations were tested: butt welding in 100…

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…

Different aluminium alloys were joined by friction stir welding (EN AW-5754-H14 to sheets of the same material, extruded profile EN AW-6063-T6 sheets to high pressure die cast EN AC-46000) and characterised by x-ray and microscopy studies, and the m…

The weldability of magnesium alloys by friction stir welding was studied using three die-cast alloys of thickness 6 mm (AM50 and AM60 Mg-Al-Mn alloys; AZ91 Mg-Al-Zn alloy) and one wrought alloy of thickness 6.4 mm (AZ231 Mg-Al-Zn alloy). Surface app…

Finite element models of the friction stir welding of aluminium alloys are reviewed and the results compared with experimental measurements. Contact between the pin and the workpiece is considered in two ways: frictional contact; or assuming the mat…

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…

The Skew-Stir™ variant of friction stir welding (FSW), in which the axis of the tool is at an angle to that of the machine spindle, is described. The technique provides an improved path for metal to flow around the tool during welding, resulti…

Fatigue crack initiation and propagation was studied in friction stir welded aluminium alloy 7010-T7651 and also in the parent alloy, using a combination of theoretical and experimental techniques. Finite element analysis was used to model the stres…

Dissimilar lap joints between AA 6061-T6 (Al, 1.01%Mg, 0.59%Si) and A356 (Al, 7.02%Si) aluminium alloys were fabricated by friction stir welding (FSW) and the influence of process conditions on joint microstructure evolution and mechanical propertie…

An investigation was undertaken to examine the interactions, required process adjustments and resultant joint properties associated with conventional and robotic stationary shoulder friction stir welding (SSFSW) for scaled tool geometries. In order …

A rotating data logger system was developed to investigate the influence of process parameters on tool tip temperature during friction stir spot welding (FSSW) of AA 6061-T6 and 5083-O aluminium alloy lap joints. The data logger was designed to rota…

AA 6063-T5 aluminium alloy L-shape stringers (thickness 2 mm) were friction stir welded in an overlap configuration positioned over AA 2024-T3 sheets (thickness 3 mm) using various process conditions and three different tool designs with respect to …

Synchrotron x-ray diffraction measurements were used to obtain residual stress state data for welded joints made by friction stir welding (FSW) in AA-5083-H321 aluminium alloys as a function of process parameters (rotational speed and feed rate). Bu…

The influence of tool geometry and process conditions on the lap shear strength, weld integrity and efficiency during friction stir spot welding of magnesium alloys for automotive applications was investigated. The macro- and microstructures and wel…