Residual stress engineering in friction stir welds by roller tensioning

J. Altenkirch, A. Steuwer, P. J. Withers, S. W. Williams, M. Poad, S. W. Wen

    Research output: Contribution to journalArticlepeer-review


    The authors investigate the efficacy of applying rolling pressure along the weld line in thin butt welds produced using friction stir welding (FSW) as a means of controlling the welding residual stresses. Two cases are examined and in each case, comparison is made against the as welded condition. First, for FSW of AA 2024 aluminium alloy, roller tensioning was applied during welding using two rollers placed behind and either side of the FSW tool. Very little effect was seen for the down forces applied (0, 50, 75 kN). Second, for FSW AA 2199 aluminium alloy, post-weld roller tensioning was applied using a single roller placed directly on the FS weld line. In this case, significant effects were observed with increased loading, causing a marked reduction in the longitudinal tensile residual stress. Indeed, a load of just 20 kN was sufficient to reverse the sign of the weld line residual stress. Only slight differences in Vickers hardness were observed between the different applied loads. Furthermore, unlike some methods, this method is cheap, versatile and easy to apply. © 2009 Institute of Materials, Minerals and Mining.
    Original languageEnglish
    Pages (from-to)185-192
    Number of pages7
    JournalScience and Technology of Welding and Joining
    Issue number2
    Publication statusPublished - Feb 2009


    • Neutron diffraction
    • Residual stress
    • Roller tensioning
    • Stress engineering
    • Synchrotron X-ray diffraction


    Dive into the research topics of 'Residual stress engineering in friction stir welds by roller tensioning'. Together they form a unique fingerprint.

    Cite this