TWI

AA 2219 aluminium alloy sheets (thickness 2.5 mm) were joined by friction stir welding (FSW) and an investigation was undertaken into the relationship between joint mechanical properties, the torque generated by the spindle motor and process variabl…

A kinematic approach is presented for modelling the friction stir welding process and the relationship between tool geometry and process parameters. The model was used to describe the correlation between features of the weld nugget, process paramete…

Vertical and angular truss extrusions made from 6082-T6 aluminium alloy (Al, 0.7-0.74%Mg, 1.04-1.14%Si, 0.53-0.54%Mn) were friction stir welded in a half-overlap configuration to fabricate panels for marine applications and their fatigue performance…

A cantilever type rotary bending fatigue testing machine with high speed loading capability was employed to investigate the high cycle fatigue properties of the stir zone, thermomechanically affected zone and HAZ in friction stir welded joints of va…

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…

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 …

Friction stir welding experiments were undertaken on thin sheet specimens (thickness 0.8 mm) of 5754-H111 alloys (Al, 2.7%Mg) in a butt joint configuration, and the influence of process conditions on microstructural, mechanical and corrosion propert…

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…

With regard to the production of wear resistant friction stir welding (FSW) tools by laser implantation of ceramic particles, an investigation was undertaken to examine the effect of laser implantation on tool surface hardness, abrasive wear and lif…

Friction stir welding (FSW) trials were carried out for thin HSLA-65 steel plate (6 mm thickness) to evaluate the potential benefits of using induction preheat. Other studies including tool design and multi-run welding are also evaluated as methods …

Dissimilar butt joints between A516 steel (0.15%C, 0.95%Mn, 0.03%Cr, 0.01%Ni, 0.29%Al) and Inconel 625 (Ni, 22.6%Cr, 9.4%Mo, 3.5%Nb) were fabricated by friction stir welding and recrystallisation and texture properties were investigated. Welding was…

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…

Butt joints between dissimilar aluminium alloys were fabricated by friction stir spot welding (FSSW) in order to investigate the influence of process conditions on material flow phenomena and intermixing patterns. The dissimilar joint combinations s…

An experimental study of friction stir welding (FSW) to join 2017A-T6 with 7075-T6 and 6013 aluminium alloys, by applying different welding parameters and conditions, was performed with the aim of analysing the microstructures and properties of the …

The evolution of microstructure and mechanisms occurring at the (sub)micron scale during friction stir spot welding of transformation induced plasticity (TRIP) steel were investigated. Welds were made in TRIP690 steel (0.24%C, 1.6%Al, 2%Mn, 0.3%Si, …

A short review is presented of the development of a friction stir welding process for steel and other hard metals using W-Re tool materials to produce repeatable, thick-section welds with minimal tool deformation. Issues discussed include: W, 25%Re …

The stationary shoulder friction stir welding (SSFSW) process was employed to fabricate defect-free joints in a variety of aluminium alloys and experiments were undertaken to investigate the microstructure and mechanical properties of the joints. Th…

Numerical modelling and experimental measurements were undertaken to investigate the heat flux and residual stresses during a rotary friction welding process to fabricate joints between an ASTM A36 steel pipe (0.11%C, 0.2%Si, 0.92%Mn, 0.02%Cr, 0.02%…

The main factors to be considered in the automation and robotisation of friction stir welding (FSW) and the production of one-, two- and three-dimensional welds were identified. A FSW robotic cell was developed and force control algorithms were defi…

A fully Lagrangian smoothed particle hydrodynamics method was employed to simulate the bobbin tool friction stir welding process for aluminium alloys in order to evaluate tool torque and forces as well as material flow for different advancing speeds…