This presentation will describe recent developments in the joining of Ti alloys using Friction Stir Welding (FSW). FSW is now an established production technology for Al components, and work is continuing on the development of FSW for high temperature materials including Ti alloys.

Potential benefits of the application of FSW to Ti alloys include:

• Improved weld quality
• Reduced production costs
• The ability to join conventionally unweldable Ti alloys

Ti alloys represent an extremely challenging application for FSW, due to their high strength, high melting point, and very low thermal conductivity. Recent developments at TWI have led to significantly improved results in the FSW of Ti alloys, particularly in the areas of process control and stability. Sections of sample welds, and the results of preliminary mechanical testing, will be shown.

A number of possible applications for Ti FSW will also be discussed, including the potential for rapid prototyping, and the production of tailored components using sequential FSW operations.

In summary this presentation will provide an overview of recent Friction Stir Welding development work on the joining of Ti alloys, and will highlight future areas of interest in this exciting field.