TWI Digital Library

A review is presented of the state-of-the-art of industrial friction stir welding (FSW) mass production, current trends, challenges and market demands as well as the potential of high speed complex contour welding on multi-axis FSW machinery with re…

Friction stir welding (FSW) experiments were performed on aluminium single crystals; the evolution of the grain structure and crystallographic texture from the parent material to the highly deformed region adjacent to the tool was studied, and the i…

Experimental investigations were undertaken to determine the way in which process parameters in friction stir welding (FSW) affect the distribution and quantity of embedded oxide particles in the weld zone and to elucidate the influence of such part…

Coupons with both triangular and rectangular gaps were prepared from AA 2024 aluminium alloy plate stock by friction stir welding (FSW) and volumetric defect formation was investigated by a neural network-based electronic NDE (e-NDE) technique. The …

A numerical model of the friction stir welding (FSW) process was developed by employing finite element analysis of a non-Newtonian fluid to evaluate plastic deformation and heat generation of the weld material, and was applied to the design of tool …

The weldability of 2 mm thickness thixomoulded sheets of AZ91D magnesium alloy by friction stir welding (FSW) was studied as a function of tool rotation speed (880-1750 rpm) and specimen travel speed (50-500 mm/min). The composition of the sheet was…

As part of a study investigating FSW as a method for joining the lids on copper canisters for the long term storage of nuclear waste, the development of microstructure and heat flow during the FSW process was experimentally investigated. The microst…

With regard to the production of aluminium alloy T joints for stiffened panel construction by friction stir welding (FSW), an investigation is presented into the fabrication of FSW T joints with AA 6082-T6 alloys and the influence of welding paramet…

Friction stir welding was employed to fabricate dissimilar joints between 5A06-H112 aluminium alloy (Al, 5.8-6.8%Mg, 0.5-0.8%Mn) and 304L stainless steel (0.03%C, 18-20%Cr, 8-11%Ni) and material flow behaviour was investigated by microstructure obse…

Stationary shoulder friction stir welding (SSFSW) and conventional FSW experiments were undertaken on AA 7050-T7651 alloy plates (thickness 6.3 mm) to demonstrate the advantages of SSFSW with respect to surface finish, thermal profile symmetry, HAZ …

Based on a friction model incorporating the dynamic coupling between friction and material flow in heat transfer and fluid flow models, a computational fluid dynamics (CFD) methodology was employed to study material flow during friction stir welding…

Defects and their mitigation associated with the fabrication of fluid-cooled aluminium alloy heatsinks for electronic applications are discussed. The heatsink consisted of an aluminium alloy 6063 substrate (310 x 300 mm) with a series of rectangular…

Friction stir welding (FSW) experiments were performed on 6005A-T6 (Al, 0.49%Mg, 0.61%Si) alloy plates (thickness 6 mm) using a fully instrumented CNC milling machine, and the microstructure and mechanical properties of the welded joints were invest…

The design and construction of a prototype fixture and a corner fixture for making 90 degree corner joints in aluminium alloys by friction stir welding (FSW) are described. The requirements for a FSW weld fixture are outlined. The fixtures were test…

Simultaneous double-sided friction stir welding (DFSW) experiments were undertaken on AMX 602 alloys (Mg, 6%Al, 0.5%Mn, 2%Ca) and the influence of diverse material flows caused by differing process parameters (rotation direction and travel speed) an…

With regard to the fabrication of hollow structures by the inversion friction stir welding (IV-FSW) technique, welded joints were fabricated in A-1050 and A-6061 aluminium alloy and SPCC steel sheets (thickness 2 mm) by IV-FSW and their surface appe…

As part of a project to develop a physical-mathematical model and software for thermal simulation of the friction stir welding (FSW) process, an initial version "FricSim2.2" was created and verified, using the software tool "SpotFSW" to convert the …

The incorporation of strips of copper foil in friction stir welded aluminium alloy plate was evaluated for flow visualisation without disturbing the welding process. The strips, of 0.1 mm thickness, were placed in various longitudinal and transverse…

Friction stir welding is widely applied in several industries such as manufacturing rolling stock, automotive parts and ship building. Especially, EV will be expected to popularize in these two or three decades in view of reducing CO2. The parts of …

A process model for friction stir welding (FSW) of Al-Zn-Mg alloys, used to predict HAZ microstructure and hardness, is presented. Numerical solutions (using a finite difference approach) are developed for heat generation and heat flow. Microstructu…