TWI Digital Library

Dissimilar joints between aluminium alloy AA 7075 (Al, 5.58%Zn, 2.48%Mg, 1.38%Cu) and Al, 0.5%Cu alloy were fabricated by friction stir welding (FSW) under optimised process conditions in a hybrid lap-butt weld configuration, and the microstructure …

In relation to the European funded research project HILDA (high integrity low distortion assembly) to encourage the industrial take up of friction stir welding (FSW) for structural steels, an investigation was undertaken into the microstructure and …

Thermomechanical modelling of the friction stir butt welding process in AA 5083-H18 aluminium alloys was undertaken using a CFD (computational fluid dynamics) code to describe the steady state, and simulated temperature profiles were compared with t…

Precipitation hardened copper alloy sheets (thickness 2 mm) containing Cu, 0.9-1.2%Cr, 0.06-0.09%Zr were joined by friction stir welding (FSW), process parameters were optimised to realise defect-free joints, and the microstructure and mechanical pr…

An investigation is presented into the bending properties of welded joints prepared by friction stir welding (FSW) in various structural aluminium alloys during which the influence of process conditions and alloy composition (Mg, Si, Zn levels) was …

To meet the needs of lightweight automobile design to join thin steel structures to thicker aluminium sheets, two joint geometries for high-strength friction stir welding (FSW) of dissimilar and unequal thickness sheets were developed: one involving…

The deformation microstructures formed during friction stir welding (FSW) of 7075-T6 aluminium alloy (Al, 5.76%Zn, 2.46%Mg, 1.32%Cu) were studied using SEM with electron back-scattered diffraction. The sheet thickness was 1.5 mm. The alloy was evalu…

Friction stir welds in austenitic stainless steels 316L (0.019%C, 0.87%Mn, 17.70%Cr, 12.19%Ni, 2.19%Mo) and 304 (0.040%C, 1.08%Mn, 18.10%Cr, 8.56%Ni); duplex stainless steel 329J4L (0.016%C, 0.78%Mn, 24.81%Cr, 7.27%Ni, 3.13%Mo, 0.43%Cu, 0.41%W); and…

An experimental canister welding machine was developed in order to evaluate FSW as a method of welding the copper canisters used in the long term storage of nuclear waste. Preliminary trials involved the development of a machine with sufficient stif…

To gain further understanding of the mechanism for abnormal grain growth occurring in the stir zone of friction stir welded (FSW) aluminium alloys during post weld heat treatment (PWHT), details of the grain growth phenomena were examined in commerc…

The principles of spot friction welding (SFW) and the differences between SFW and linear friction stir welding (FSW) are outlined. Displacement control and load control of SFW machines are described. Experiments were conducted using a displacement-c…

An investigation was undertaken into the efficiency and cost effectiveness of two process chains for the production of an AW-70xx aluminium alloy telescopic beam for a crane boom (length 8 m, sheet thickness 4 mm), and a comparison between friction …

The tool workpiece thermocouple (TWT) temperature measurement method was applied for optimisation of the initial welding phases (plunge and dwell) in conventional FSW (friction stir welding) and FSSW (friction stir spot welding), and an analysis of …

A review is presented of various models developed to understand the effects of thermal cycles and metal flow behaviour on the microstructure and properties of welded joints fabricated by friction stir welding of steel, and a comprehensive numerical …

Additive friction surfacing (AFS) is a variant of friction surfacing (FS) where multiple layers of feedstock material can be deposited to generate a near-net shape part. AFS has the potential to yield significantly higher deposition rates than tradi…

A discussion is presented on developments in polycrystalline cubic boron nitride (PCBN) tool design for use in the friction stir welding of high temperature materials such as steels. Improvements in tool material grades, tool design and FSW equipmen…

The Taguchi method was employed to determine optimum process parameters for friction stir welding of dissimilar joints between AA 6061 (Al, 0.84%Mg, 0.54%Si, 0.4%Fe, 0.24%Cu) and AA 7075 (Al, 5.58%Zn, 2.28%Mg, 1.6%Cu) aluminium alloys. Welding was p…

A pinless tool with involute grooves on its shoulder surface was designed to facilitate friction stir spot welding (FSSW) of 2024-T3 aluminium alloy (Al, 3.8-4.9%Cu, 1.2-1.8%Mg, 0.3-0.9%Mn) sheets (thickness 1.5 mm) and the influence of process para…

An integrated multi-physics model was employed to predict the temperature distribution, the post-weld grain size distribution and the local subgrain size distribution around the pin during friction stir welding (FSW) of 6061 aluminium alloys. The mu…

Models were developed for the temperature distribution and material flow during friction stir welding. Both friction and material shearing were presumed to generate heat, and finite element analysis was used to determine the temperature distribution…