No description available.

This thesis describes a number of approaches to the problems of automatic defect detection in ultrasonic Time of Flight Diffraction (TOFD) and X-ray radioscopic images of butt welds in steel plate. A number of novel image segmentation techniques are developed, two of which feature the use of backpropagation artificial neural networks. Two new methods for defect detection in ultrasonic TOFD images are described - the first uses thresholding of individual one-dimensional A-scans, and the second uses a neural network to classify pixels using two dimensional local area statistics. In addition, three new methods for defect detection in radioscopic images are described - the first is based on the use of two conventional spatial filters, the second uses grey level morphology to replace the 'blurring' stage of conventional "blur and subtract' procedures, and the third uses a neural network to classify pixels using raw grey level data at the input layer. It is considered that all five methods which have been developed show novelty in their methodology, design and implementation, most specifically in that (1) no previous methods for automatic defect detection in TOFD images, (2) very few successful implementations of grey level data processing by neural networks, and (3) few examples of local area segmentation of 'real' textured images for automatic inspection have been reported in the literature. The methods developed were tested against data interpreted by skilled NDT inspectors. In the case of the ultrasonic TOFD image processing, both automatic methods performed exceptionally well, producing results comparable to that of a human inspector. In the case of the radioscopic image processing, the ANN method also produced results comparable to that achieved by a human inspector and also gave comparable or consistently better results than those obtained using a number of existing techniques.

This study was undertaken with the objective of determining the effect of gap distance on the weld bead geometry and the mechanical properties of the weldments. Low-alloyed and low carbon steel plates were welded under different conditions where each weldment had different gap distance and weld bead grooves. The influences of welding parameters namely, welding speed, current and voltage on the weld bead were examined in terms of weld bead penetration and heat affected zone and weld metal zone hardness variations.

No description available.

Presented master thesis deals with computational modelling (simulation) of welding process. Its main goal is to determine the residual stresses and deformations arising after welding. SYSWELD and ANSYS are used for simulation, both based on the finite element method. Specifically, the processes of welding fillet and butt welds are solved. Results from both software are compared with each other and verified by experimental results.

Thesis (MScAgric )--Stellenbosch University, 2004. / ENGLISH ABSTRACT: In an attempt to combat some of the pathogens that are associated with trunk diseases and disorders of grapevines, research in this thesis focused on the taxonomy and pathological aspects of Coniellai/Pilidiella, Botryosphaeria and Phomopsis spp. Previously, conidial pigmentation was used to separate Pilidiella from Coniella. Recently, however, the two genera have been regarded as synonymous, with the older name, Coniella, having priority. The most important species in the Coniellai/Pilidiella complex of grapevines is C. diplodiella (Speg.) Petr. & Syd., the causal organism of white rot of grapevines. Previous studies found it difficult to distinguish between C. diplodiella and C. fragariae (Oudem.) B. Sutton, which is known to occur in soil and caused leaf diseases of Fragaria and Eucalyptus. Both these species have previously been reported from South Africa. None of the reports on C. diplodiella could be scientifically substantiated; therefore it is still a quarantine organism. However, this status has been questioned. Based on sequence analyses of the internal transcribed spacer region (ITS 1, ITS 2), 5.8S gene, large subunit (LSU) and elongation factor 1- α gene (EF l- α) from the type species of Pilidiella and Coniella, Coniella was separated from Pilidiella, with the majority of taxa residing in Pilidiella. Pilidiella is characterised by species with hyaline to pale brown conidia (avg. length: width >1.5), with Coniella having dark brown conidia (avg. length: width ≤1.5). Pilidiella diplodiella, previously C. diplodiella, causal organism of white rot of grapevines, was shown to be an older name for C. petrakii. This fungus is present in South Africa and is therefore no longer of quarantine importance. Based on analyses of the histone (H3) gene sequences of isolates in the P. diplodiella species complex, P. diplodiella was separated from a newly described species, P. diplodiopsis. A new species, P. eucalyptorum, is proposed for isolates formerly treated as C. fragariae, associated with leaf spots of Eucalyptus spp. This species clustered basal to Pilidiella, and may represent yet a third genus within this complex. Pilidiella destruens was newly described as anamorph of Schizoparme destruens, which is associated with twig dieback of Eucalyptus spp. in Hawaii. The genus Botryosphaeria Ces. & De Not. are known to be cosmopolitan, with broad host ranges and geographical distributions. Several saprotrophic species have been reported from grapevines, while others are severe pathogens of this host. These species include B. dothidea (Moug.: Fr.) Ces. & De Not., B. parva Pennycook & Samuels, B. obtusa (Schwein.) Shoemaker, B. stevensii Shoemaker, B. lutea A.J.L. Phillips and B. ribis Grossenb. & Duggar. Species reported from South Africa as grapevine pathogens are B. obtusa, B. dothidea, B. ribis and B. vitis (Schulzer) Sacco. In the present study, morphological, DNA sequence data (ITS 1, 5.8S, ITS 2 and EFI-α) and pathological data were used to distinguish 11 Botryosphaeria spp. associated with grapevines from South Africa and other parts of the world. Botryosphaeria australis, B. lutea, B. obtusa, B. parva, B. rhodina and a Diplodia sp. were confirmed from grapevines in South Africa, while Diplodia porosum, Fusicoccum viticlavatum and F. vitifusiforme were described as new species. Although isolates of B. dothidea and B. stevensii were confirmed from grapevines in Portugal, neither of these species, nor B. ribis, were isolated in this study. All grapevine isolates from Portugal, formerly presumed to be B. rib is, are identified as B. parva based on EF1-α sequence data. Artificial inoculations on grapevine shoots showed that B. australis, B. parva, B. ribis and B. stevensii are more virulent than the other species studied. The Diplodia sp. collected from grapevine canes was identified as morphologically similar, but phylogenetically distinct from D. sarmentorum, while D. sarmentorum was confirmed as anamorph of Otthia spiraeae, the type species of the genus Otthia (Botryosphaeriaceae). A culture identified as O. spiraeae clustered within Botryosphaeria, and is thus regarded as a probable synonym. These findings confirm earlier suggestions that the generic concept of Botryosphaeria should be expanded to include genera with septate ascospores and Diplodia anamorphs. The genus Phomopsis (Sacc.) Bubak contains many species that are plant pathogenic or saprotrophic. Ten species are known from grapevines. However, only two have been confirmed as being pathogenic, namely P. viticola (Sacc.) Sacc., causal organism of Phomopsis cane and leaf spot and P. vitimegaspora Kuo & Leu (teleomorph Diaporthe kyushuensis Kajitani & Kanem.), causal organism of swelling arm disease of grapevines. P. amygdali (Delacr.) 1.1. Tuset & M.T. Portilla, a known pathogen from Prunus sp., was shown to be a possible pathogen of grapevines in a previous study. D. perjuncta Niessl. causes bleaching of dormant canes only and is therefore of little importance as a grapevine pathogen. Recently a number of Phomopsis isolates were obtained from grapevines in the Western Cape province of South Africa. Isolations were made from Phomopsis-like symptoms, pruning wounds and asymptomatic nursery plants. These isolates showed great variation in morphology and cultural characteristics. Earlier taxonomic treatments of Phomopsis, based species identification on host specificity, cultural characteristics and morphology. Recent studies have indicated that these characteristics can no longer be used to distinguish species of Phomopsis due to wide host ranges and morphological plasticity of some species. The use of anamorph/teleomorph relationships in species identification is also untenable, since Diaporthe teleomorphs have only been described for approximately 20% of the known Phomopsis species. In this study morphological data, DNA sequences (ITS-I, 5.8S, ITS-2) and pathogenicity data were combined to distinguish Phomopsis spp. from grapevines. Fifteen species of Phomopsis were delineated by phylogenetic analysis of ITS sequence data. Diaporthe helianthi, a sunflower pathogen, was reported from grapevines for the first time, with a further six, unknown species also distinguished. Three different clades contained isolates previously identified as D. perjuncta. Based on type studies, it appeared that the name D. viticola was available for collections from Portugal and Germany, a new species, D. australafricana, was proposed for South African and Australian isolates, formerly treated as D. perjuncta or D. viticola. An epitype specimen and culture were designated for D. perjuncta. This species was distinguished from D. viticola and D. australafricana based on morphology and DNA phylogeny. Artificial inoculations of green grapevine shoots indicated that, of the species tested, P. amygdali, a known pathogen of peaches in the USA, and P. viticola were the most virulent. / AFRIKAANSE OPSOMMING: In 'n poging om sommige patogene geassosieer met stamsiektes en syndrome, te beveg, het die navorsing in die tesis gefokus op die taksonomie en patologiese aspekte van ConiellaiPilidiella, Botryosphaeria en Phomopsis spp Voorheen is konidium pigmentasie gebruik om Pilidiella (hialien tot ligbruin konidia) van Coniella (donkerbruin konidia) te skei. Onlangs is hierdie twee genera egter as sinoniem beskou met die ouer naam, Coniella, wat voorkeur gekry het. Die belangrikste spesies in die ConiellaiPilidiella kompleks van wingerd is C. diplodiella (Speg.) Petr. & Syd., die veroorsakende organisme van witvrot van wingerd. Vorige studies het dit moeilik gevind om te onderskei tussen C. diplodiella en C. fragariae (Oudem.) B. Sutton, wat bekend is dat dit in grond voorkom en ook blaarsiektes van Fragaria en Eucalyptus veroorsaak. Beide hierdie spesies is tevore in Suid-Afrika aangemeld. Geen van die aanmeldings van C. diplodiella is egter wetenskaplik bewys nie en daarom is dit steeds 'n kwarantyn organisme. Hierdie kwarantyn status is egter bevraagteken. Op grond van DNS volgordes van die interne getranskribeerde spasieerder area ("ITS 1", "ITS2"), die 5.8S rRNS geen, die groot ribosomale subeenheid ("LSU") en die verlengingsfaktor 1-α geen ("EF-lα") van die tipe spesies van Pilidiella en Coniella, is Coniella van Pilidiella geskei, met die meerderheid van die taxa wat binne Pilidiella resorteer. Pilidiella word gekarakteriseer deur spesies met hialien tot ligbruin konidia (gem. lengte: breedte > 1.5), in teenstelling met die donkerbruin konidia van Coniella (gem. lengte: breedte ≤ 1.5). Daar is verder bewys dat Pilidiella diplodiella, voorheen C. diplodiella, veroorsakende organisme van witvrot van wingerd, die ouer naam van C. petrakii is. Hierdie swam is teenwoordig in Suid-Afrika en P. diplodiella is dus nie meer van kwarantyn belang nie. Op grond van analises van die histoon (H3) volgordes van spesies in die P. diplodiella spesies kompleks, is P. diplodiella geskei van 'n nuut beskryfde spesie, P. diplodiopsis. 'n Nuwe spesie, P. eucalyptorum, is ook voorgestel vir isolate voorheen beskou as C. fragariae, geassosieer met blaarvlek van Eucalyptus spp. Hierdie spesie het basaal van Pilidiella gegroepeer en mag moontlik nog 'n derde genus binne hierdie kompleks verteenwoordig. Pilidiella destruens is nuut as anamorf van Schizoparme destruens beskryf, wat geassosieer word met loot terugsterwing van Eucalyptus spp. in Hawaii. Die genus Botryosphaeria Ces. & De Not. is bekend as kosmopolitaans met 'n wye gasheerreeks en geografiese verspreiding. Verskeie saprofitiese spesies is aangemeld vanaf wingerd, terwyl ander ernstige patogene van hierdie gasheer is. Laasgenoemde spesies sluit in B. dothidea (Moug.: Fr.) Ces. & De Not., B. parva Pennycook & Samuels, B. obtusa (Schwein.) Shoemaker, B. stevensii Shoemaker, B. lutea A.1.L. Phillips en B. ribis Grossenb. & Duggar. Spesies aangemeld in Suid-Afrika as wingerdpatogene, is B. obtusa, B. dothidea, B. ribis en B. vitis (Schulzer) Sacco In hierdie studie is morfologiese, DNS volgorde data ("ITSl", "ITS2", 5.8S en "EF-Iα") en plantpatologiese data gebruik om II Botryosphaeria spesies, geassosieer met wingerde in Suid-Afrika en verskeie ander werelddele, te onderskei. Botryosphaeria australis, B. lutea, B. obtusa, B. parva, B. rhodina en 'n Diplodia sp. is bevestig van wingerde in Suid-Afrika, terwyl Diplodia porosum, Fusicoccum viticlavatum en F. vitifusiforme as nuwe spesies beskryf is. AIhoewel isolate van B. dothidea en B. stevensii bevestig is van wingerde in Portugal, is geen van hierdie spesies en ook nie B. ribis geïsoleer nie. AIle isolate vanaf wingerd in Portugal, voorheen beskou as B. rib is, is as B. parva op grond van hul "EF-lα" volgordes geïdentifiseer. Uit kunsmatige isolasies gemaak op wingerdlote is die gevolgtrekking gemaak dat B. australis, B. parva, B. ribis en B. stevensii meer virulent is as die ander spesies wat bestudeer is. Die Diplodia sp. versamel vanaf wingerdlote is geïdentifiseer as morfologies eenders, maar filogeneties verskillend van D. sarmentorum, terwyl D. sarmentorum bevestig is as die anamorf van Otthia spiraeae, die tipe spesie van die genus Otthia (Botryosphaeriaceae). 'n Kultuur wat as 0. spiraeae geïdentifiseer is, het binne Botryosphaeria gegroepeer, en word dus as 'n moontlike sinoniem beskou. Hierdie bevindinge bevestig vroeëre voorstelle dat die generiese konsep van Botryosphaeria uitgebrei behoort te word om genera met gesepteerde askospore en Diplodia anamorwe in te sluit. Die genus Phomopsis (Sacc.) Bubak bevat verskeie spesies wat as of plantpatogenies, of saprofities, beskryf is. Tien spesies is bekend op wingerd. Slegs twee is as patogenies bevestig, naamlik P. viticola (Sacc.) Sacc., veroorsakende organisme van loot-en-blaarvlek ("streepvlek") en P. vitimegaspora Kuo & Leu (teleomorf Diaporthe kyushuensis Kajitani & Kanem.), veroorsakende organisme van geswelde arm van wingerd. In 'n vroeëre studie is bevind dat P. amygdali (Delacr.) 1.1. Tuset & M.T. Portilla, 'n bekende patogeen van Prunus sp., moontlik ook 'n patogeen van wingerd mag wees. D. perjuncta Niessl. veroorsaak egter net verbleiking van dormante lote en is dus van min belang as 'n wingerd patogeen. Gedurende die afgelope twee jaar is verskeie Phomopsis isolate van wingerde in die Wes-Kaap provinsie van Suid-Afrika verkry. Isolasies is gemaak van Phomopsis-agtige simptome, snoeiwonde en asimptomatiese kwekeryplante. Die isolate verkry uit hierdie materiaal het groot variasie ten opsigte van morfologie en kultuureienskappe getoon. Vroeëre taksonomiese verhandelings van Phomopsis het spesies-identifikasie op gasheerspesifisiteit, kultuureienskappe en morfologie gebasseer. Onlangse studies het egter getoon dat, weens wye gasheerreekse en morfologiese plastisiteit van somnuge spesies, hierdie eienskappe me meer gebruik kan word om Phomopsis spesies te identifiseer nie. Die gebruik van anamorflteleomorf verwantskappe in die identifikasie van Phomopsis spesies ook onbruikbaar omdat Diaporthe teleomorwe vir slegs ongeveer 20% van die bekende Phomopsis spesies beskryf is. Die huidige studie het dus morfologiese data, DNS volgordes ("ITS 1", 5.8S, "ITS2") en patogenisiteitsdata gekombineer ten einde Phomopsis spp. vanaf wingerd te identifiseer. Vyftien Phomopsis spesies is deur die filogenetiese analise van die interne getranskribeerde spasieerder area ("ITS") volgordes geskei. Diaporthe helianthi, 'n bekende patogeen van sonneblomme, is vir die eerste maal op wingerd aangeteken, terwyl 'n verdere ses, tans onbekende spesies van Phomopsis ook geidentifiseer is. Drie verskillende groepe het isolate bevat wat voorheen as D. perjuncta geidentifiseer is. Gebasseer op studies van tipes, het dit voorgekom dat die naam D. viticola beskikbaar is vir isolate uit Portugal en Duitsland. 'n Nuwe spesie, D. australafricana, is voorgestel vir Suid-Afrikaanse en Australiese isolate wat voorheen behandel is as D. perjuncta of D. viticola. 'n Epitipe monster en kultuur is vir D. perjuncta benoem. Hierdie spesie is van D. viticola en D. australafricana onderskei op grond van morfologie en DNS filogenie. Kunsmatige inokulasies van groen wingerdlote het getoon dat P. amygdali, bekende perske patogeen, en P. viticola die mees virulent was.

O desempenho de serras de fita bimetálica depende principalmente das características da junção de suas extremidades, executada pelo processo de soldagem topo-a-topo por centelhamento. Este é um processo de soldagem por resistência, constituído por um aquecimento elétrico, seguido por um rápido forjamento dos materiais. O presente trabalho tem como objetivo, estudar a influência da variação da corrente elétrica, força de recalque e tratamento térmico de revenimento nas microestruturas e propriedades mecânicas das juntas soldadas topo-a-topo por centelhamento. Neste estudo, foram utilizadas amostras de serras de fita bimetálica de 27 mm de largura e 0,9 mm de espessura. O material é um composto bimetálico constituído por aço rápido M42 para os dentes, soldado a um corpo de aço carbono de baixa liga e alta resistência D-6a. As microestruturas e as propriedades mecânicas das amostras soldadas foram investigadas. Foi observado que os parâmetros de soldagem e o revenimento afetam as propriedades mecânicas. A dureza na seção transversal à linha central da solda apresentou valores levemente superiores à respectiva dureza na seção longitudinal. Amostras não revenidas resultaram em maior resistência à tração, associada ao parâmetro de menor temperatura de revenimento. Ficou evidenciado que o revenimento reduziu a dureza e a resistência à tração de todas as amostras. / The performance of bimetal band saw blades depends mainly on the features of joining their ends, carried out by flash butt welding process. This is a resistance welding method, which consists of electrical heating followed by a fast material forging. The present work has the objective of studying the influence of changing the electrical current, upset force and tempering heat treatment on the microstructures and mechanical properties of the flash butt welded joints. In this study, samples of bimetal band saw blades having width of 27 mm and thickness of 0.9 mm were employed. The material consists of a composite M42 high speed steel for the teeth welded together with a D-6a ultra-high strength carbon low alloy steel for the backer. The microstructure and mechanical properties have been investigated. It is pointed out that welding parameters and tempering affected the mechanical properties. The transversal hardness to the welding center line has shown values slightly higher than the respective longitudinal hardness. Non-tempered samples gave the highest tensile strength with the parameter of lowest tempering temperature. It is also found that the tempering reduces the hardness and the tensile strength of all samples.

Em geral, um problema importante em um sistema de soldagem robotizado, ou com manipuladores automáticos, é a necessidade de uma trajetória ser reprogramada quando a forma ou a posição das peças mudam. Como solução a esse problema é proposto um método que utiliza técnicas de visão computacional, para assim detectar a trajetória de soldagem em juntas de topo. O método deve ser dinâmico permitindo a identificação de juntas de topo com cantos não próximos, linhas não retas e tamanhos diferentes entre as peças, assim como apresentar robustez contra variáveis desfavoráveis do ambiente industrial como riscos nas peças ou no fundo e mudanças de luminosidade. A trajetória é detectada baseando-se na linha de bordas da imagem global e adicionalmente trabalha-se sobre duas características da linha de solda: distância quase constante entre linhas paralelas e pixels de linha de solda com menor intensidade de luminosidade que as bordas. Uma etapa é proposta para robustez do método sobre linha de bordas descontinuas e possíveis erros em ponto inicial e final de solda. O trabalho proposto é validado com distintas configurações de junta de topo, como com cantos de peças não coincidentes, linha de solda não reta e diferentes orientações de peças. Os pontos da trajetória de solda obtidos são comparados com uma linha de solda considerada ideal, resultando em uma média e desvio padrão geral inferiores à um valor de 0,5 mm. Uma validação experimental é realizada com uma solda executada por um robô industrial seguindo os pontos de solda detectados, com os resultados demostrando que o método efetivamente pode definir uma trajetória de solda para aplicações industriais robotizadas. / In general, one of the most important problems in a robotic welding system, or in automatic manipulations, is the requirement of a path trajectory to be reprogramed when the shape or the position of the welding pieces are changed. In order to detect the welding seam in butt joints, a method that makes use of computational vision techniques is proposed. The method needs to be dynamic against variation in the configuration of the pieces, so as curved or not straight seam lines, not coincident corners; beside of that, it must to present robustness against unfavorable variables of the industrial environment, so as scratches in the pieces or illumination changes. Two features of the welding line are taken into account to develop the method: almost constant distance between parallel seam lines and darker pixels in the center of the seam than in the borders. Moreover a robustness step is proposed over two weaknesses of the method: discontinuities in the edges of the welding line and possible errors in the location of the start and end welding points. The validation step of the method involves different configuration of butt joints, as pieces without corner being coincident, not straight welding line and different orientations. The points of the welding seam detected by the method, are compared against a set of welding points considered as an ideal set of points, getting as results a mean and standard deviation lower than ± 0.5 mm. An experimental test is carried out by an industrial robot that welds two pieces following the welding line points, with the results showing that the method can effectively define a welding trajectory for industrial robotics applications.

Butt fusion welding process is an extensively used method of joining for high density polyethylene (HDPE) pipe. With the increasing number of HDPE resin and pipe manufacturers and the diversity of industries utilising HDPE pipes, a wide range of different standards have evolved to specify the butt fusion welding parameters with inspection and testing methods, to maintain quality and structural integrity of welds. There is a lack of understanding and cohesion in these standards for the selection of welding parameters; effectiveness, accuracy, and selection of the test methods and; correlation of the mechanical properties to the micro and macro joint structure. The common standards (WIS 4-32-08, DVS 2207-1, ASTM F2620, and ISO 21307) for butt fusion welding were used to derive the six welding procedures. A total of 48 welds were produced using 180 mm outer diameter SDR 11 HDPE pipe manufactured from BorSafe™ HE3490-LS black bimodal PE100 resin. Three short term coupon mechanical tests were conducted. The waisted tensile test was able to differentiate the quality of welds using the energy to break parameter. The tensile impact test due to specimen geometry caused the failure to occur in the parent material. The guided side bend specimen geometry proved to be too ductile to be able to cause failures. A statistical t-test was used to analyse the results of the short term mechanical tests. The circumferential positon of the test specimen had no impact on their performance. Finite element analysis (FEA) study was conducted for the long term whole pipe tensile creep rupture (WPTCR) test to find the minimum length of pipe required for testing based on pipe geometry parameters of outer diameter and SDR. Macrographs of the weld beads supplemented with heat treatment were used to derive several weld bead parameters. The FEA modelling of the weld bead parameters identified the length to be a key parameter and provided insight into the relationship between the geometry of the weld beads and the stresses in the weld region. The realistic bead geometry digitised using the macrographs contributed a 30% increase in pipe wall stress due to the stress concentration effect of the notches formed between the weld beads and the pipe wall. The circumferential position of the weld bead had no impact on the pipe wall stresses in a similar manner to the results of the different mechanical tests. IV Nanoindentation (NI) and differential scanning calorimetry (DSC) techniques were used to study the weld microstructure and variation of mechanical properties across the weld at the resolutions of 100 and 50 microns, respectively. NI revealed signature 'twin-peaks and a valley' distribution of hardness and elastic modulus across the weld. The degrees of crystallinity obtained from DSC followed the NI pattern as crystallinity positively correlates with the material properties. Both techniques confirm annealing of the heat affected zone (HAZ) material towards the MZ from the parent material. The transmission light microscopy (TLM) was used to provide dimensions of the melt zone (MZ) which displays an hour glass figure widening to the size of the weld bead root length towards the pipe surfaces. Thermal FEA modelling was validated using both NI and TLM data to predict the HAZ size. The HAZ-parent boundary temperature was calculated to be 105 ⁰C. The 1st contribution of the study is to prove the existence of a positive correlation between the heat input calculated from FEA and the energy to break values obtained from the waisted tensile test. The 2nd contribution providing the minimum length of pipe for WPTCR based on the pipe dimensions. The 3rd contribution is the recommendation for the waisted tensile test with the test using the geometry designed to minimise deformation of the loading pin holes. The 4th contribution related the weld bead parameters to pipe wall stresses and the effect of notches as stress concentrators. The 5th contribution is a new method of visualising a welding procedure that can be used to not only compare the welding procedures but also predict the size of the MZ and the HAZ. The 6th contribution of the study is the proposal of new weld bead geometry that consist of the MZ bounded by the HAZ, for butt fusion welded joints of HDPE pipes.

Stationary shoulder friction stir welding (SSFSW) is a recently developed variant of conventional friction stir welding (FSW). Recent studies have shown that SSFSW can join high strength aluminum alloys with improved mechanical strength and reduced distortion as a result of a narrower and more uniform thermal profile. However, a lack of understanding on the residual stress development in the SSFSW process makes it difficult to assess the structural integrity and delays a widespread application of this technique to industry. This dissertation reports the first systematic investigation into the development of residual stress induced by the SSFSW process and comparison between SSFSW and FSW techniques. Welding residual stresses were experimentally assessed with both the contour method and neutron diffraction. The weld microstructure and hardness distributions were characterized and used to understand the formation of residual stresses during the welding process. The results have shown that for both FSW and SSFSW processes, the residual stresses distribute in the form of ‘M’ shaped profile while the magnitude and size of tensile residual stress zone were effectively reduced (by 25%) in the SSFSW process, even when input welding power was identical. Other improvements seen in the SSFSW process include a reduction in the heat affected zone width, an increase in the minimum hardness and a more uniform through-thickness microstructure and hardness. The dominating welding process parameter affecting the welding residual stress was travel speed as compared to rotation speed and tool downforce. With a 90 degree shaped shoulder, SSFSW has been shown to produce defect-free T-sections by dual fillet welds. For these components, an asymmetrical distribution of microstructure, hardness and residual stresses were found as a consequence of the thermal effects induced by second weld on the first weld. The material softening caused by the first weld provides the potential of utilizing a lower heat input on the subsequent pass so as to optimize the welding parameters.