Friction Stir Spot Welding (FSSW) has been developed from the conventional Friction Stir Welding (FSW) process, developed at The Welding Institute (TWI). FSSWs have been done without the keyhole being eliminated. Elimination of the keyhole would result in the process being more commercially viable. This dissertation focuses on an attempt of eliminating the keyhole using a retractable pin tool as well as a comparison of the weld integrity of a FSSW to that of a conventional Resistance Spot Weld (RSW). Welds were conducted on aluminium alloy 6063 T4. Comparisons between different weld procedures were done. Further analysis of the weld integrity between FSSW and RSW were conducted, comparing tensile strengths, microstructure and hardness. For the above welding procedure to take place, the current retractable pin tool, patented by PE Technikon, was redesigned. Problems associated during the welding process and the results obtained are documented. Reasons for the keyhole not being eliminated as well as recommendations for future work in the attempt to remove the keyhole are discussed.

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Thesis (Ph.D.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering, 1980. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND SCIENCE. / Includes bibliographical references. / by Chang-Shung Chai. / Ph.D.

The purpose of the present study is to obtain insight into the formation, behaviour and magnitude of welding-induced residual stresses and distortions resulting from welding nozzles onto cylindrical pressure vessels. A hybrid methodology that comprises numerical analysis, experimental measurements and empirical calculations is used in the present study. The welding process induces a high thermal gradient on the material due to non-uniform temperature distribution; thereby causing the portion of the material that is exposed to high temperatures to expand. However, the relatively cooler material portion that is away from the weld pool resists such expansion, thereby subjecting the structure to stresses and distortions around the fusion zone (FZ) and the heat-affected zone (HAZ). Over the last two decades a number of studies have been done in an effort to predict the effect of welding-induced residual stresses on the integrity of welded structures. However, to this end, such studies have focussed on analysing residual stresses on bead-on-plate, plate-to-plate and [to a less extent] on pipe-to-pipe weld joints. Fewer studies have looked at nozzle-cylinder joints of pressure vessels as is the case in this study. The second chapter gives a detailed review of applicable literature. The constitutive model described in the third chapter includes a two-phase sequentially-coupled thermo-mechanical analysis, which incorporates metallurgical effects. The non-linear transient problem is solved using an axisymmetric 2D model with ‘element birth’ technique, developed on ABAQUS. The first phase comprises the thermal analysis based on Goldak’s moving heat source model that is used to determine temperature histories. The second phase is a sequel stress/strain analysis wherein the temperature fields are used as input loads. The results discussed in chapters three and four show that there is a high concentration of residual stresses close to the weld centre-line, and these die down as distance away from centre-line increases. It is also shown that the inside surface is under tensile stresses, while the outer surface is under compressive stress, whose magnitude approaches yield strength of the material. Axial deflections of up to 0.384mm and radial shrinkage of 0.0237mm are observed. Distortion decreases as distance away from weld centre-line increases. Minimum axial shrinkage, which is close to zero, is observed at the restrained end. The analytical results show adequate corroboration and agreement with the experimental measurements. A number of mitigation techniques are suggested in order to alleviate the impact of residual stress and distortions on fatigue performance of welded structures. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2012.

Bibliography: leaves 191-198. / xxi, 201 leaves : ill. ; 30 cm. / Title page, contents and abstract only. The complete thesis in print form is available from the University Library. / Examines the mechanisms controlling the dilution, geometry and wear performance of weld- deposited high-chromium white iron surface layers. Focuses on layers deposited by mechanised flux-cored-arc welding, as this process achieves higher deposition rates than manual-metal-arc welding and affords a greater degree of control over individual welding variables. / Thesis (Ph.D.)--University of Adelaide, Dept. of Mechanical Engineering, 1999

Thesis (M. Sc.(Metallurgy))-University of Pretoria, 2006. / Includes bibliographical references (leaves 62-65). Available on the Internet via the World Wide Web.

Thesis (Ph.D.)--University of Wollongong, 2004. / Typescript. Includes bibliographical references: leaf 305-322.

Thesis (Ph. D.)--Virginia Polytechnic Institute and State University, 1994. / Vita. Abstract. Includes bibliographical references (leaves 138-141). Also available via the Internet.

Thesis (Ph. D.)--University of Missouri-Columbia, 2005. / The entire dissertation/thesis text is included in the research.pdf file; the official abstract appears in the short.pdf file (which also appears in the research.pdf); a non-technical general description, or public abstract, appears in the public.pdf file. Title from title screen of research.pdf file viewed on (November 13, 2006) Vita. Includes bibliographical references.