TWI Digital Library

The mechanical properties of the parent metals and friction stir welded joints in aluminium alloy 6 mm plate 2014A, 7075 and 5083 are summarised. CTOD and J fracture toughness results are reported for the parent metal and up to five different region…

Friction stir welded joints in 2024-T351 Al-Cu-Mg alloy were subjected to fatigue testing to evaluate the suitability of this welding process for aircraft manufacture. Aluminium alloy (Al, 3.8-4.9%Cu, 1.2-1.8%Cu, 0.5%Si, 0.5%Fe, 0.2%Zr) of 6.35 mm (…

An investigation is presented into the effect of frictional heating on joint behaviour during friction stir welding (FSW) between aluminium alloy 6063 and mild steel S45C, the cross-section microstructure of the weld interface, and the welding mecha…

The friction stir welding of dissimilar aluminium alloys for the production of aircraft structural components was investigated. Welds were made between alloys 7040 and 7449 pre-aged to obtain a defined temper after post-weld ageing. Alloy 7040 was a…

The formability of friction stir welded aluminium alloy tailored welded blanks (TWBs), as used in the automotive industry, was analysed, based on hardening exponent and anisotropy values obtained from tensile tests (parallel and normal to loading di…

An experimental study was carried out on friction stir welded aluminium alloy tailored welded blanks (TWB's) to determine mechanical properties and microstructural characteristics in order to evaluate friction stir welding (FSW) as a feasible method…

Friction stir welding (FSW) was carried out on AZ31 magnesium alloy (Mg, 3%Al, 1%Zn) plates of thickness 6 mm in order to examine the relationship between weld microtexture and tensile properties. Orientation imaging microscopy was used to examine m…

The effects of friction stir welding (FSW) parameters and tool geometry on the forces and torques generated during the FSW of four aluminium alloys were studied. The alloys were 6082-T6 (6.45 mm), 5083-H111 (6.55 mm), 2014-T6 (5.9 mm) and 7075-T7351…

The decision to use friction stir welding (FSW) in the manufacture of aluminium alloy car wheels by Simmons Wheels, Sydney, Australia is described. Rim sections are formed from alloy 6061 in thicknesses of 4-6 mm. These are attached to cast or forge…

Friction stir spot welded joints in aluminium alloy 6061-T4 were studied. Sheet of 1, 1.5, 2, and 3 mm thickness was friction stir welded to sheet of 3 mm thickness, using welds of 8-18 mm in length (equivalent in area to circular resistance spot we…

In the realm of armor steels, the relationship between hardness and ballistic performance is crucial. Different hardness levels can lead to various modes of failure upon ballistic impact. However, when armor-grade steel plates undergo welding, the b…

Friction stir welding (FSW) is a solid-state welding process, particularly suitable for aluminum alloys. The process allows the production of welds with a high seam strength and low distortion. Despite these benefits, irregularities can occur during…

An investigation was undertaken into the development and wear performance of friction stir welding (FSW) tools made from precipitation strengthened Ir-containing nickel-based superalloys (Ni, 25%Ir, 14%W, 4%Al) during FSW of Ti, 6%Al, 4%V alloys. Th…

A report is presented into the challenges faced when developing thermal, thermomechanical and flow models of the friction stir welding process, such as the evolution of predictive models, a method to find the correct contact state variable, and the …

A control concept for friction stir welding (FSW) of structural steels was developed based on a closed loop architecture that limits the heat input during the welding process according to the continuously monitored value of the magnetic permeability…

Thermodynamic modelling and experimental measurements were employed to investigate the influence of intermetallic compound formation on the shear strength of dissimilar joints between an aluminium alloy and ultra-high strength steel fabricated by fr…

A 3D fully coupled computational fluid dynamics model was established to investigate the heat generation and material flow during friction stir welding, and the measured tool torque and axial force were used to characterise the contact conditions (f…

Dissimilar lap joints between ASTM A36 low carbon steel and Inconel 625 (Ni, 21.4%Cr, 9.65%Mo, 3.2%Nb, 2.6%Fe) were fabricated by friction stir welding (FSW) and the effects of process parameters on microstructure and hardness were investigated. FSW…

A qualitative and discrete quantitative approach was adopted to develop a generalised electronic NDE (e-NDE) algorithm for identifying erratic friction stir welding (FSW) indications contained in the tool force feedback signals as low and high frequ…

A report is presented into the friction stir welding (FSW) fabrication of an aluminium deck for a pedestrian bridge over the Petite Decharge river (Alma, Quebec, Canada), incorporating the design and manufacturing of extrusions, FSW tools and a syst…