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Friction stir welding, using zero down force, has been successfully demonstrated at TWI on aluminium plate up to 25mm. The technique uses a 'floating' bobbin shaped tool and penetrates the joint line either directly, or from a milled recess, in the material's edge.
Successful demonstrations have shown that thick section friction stir welds up to 25mm can be performed using TWI's large purpose-built FSW machine.
The technique is ideal for joining low temperature softening materials such as 6082 aluminium. TWI has also been successful with joining several two and seven thousand high strength aluminium alloys, as well as grade 5083. The process lends itself to joining closed sections where conventional use of a well supported backing bar is difficult or impossible.
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