Considerable residual stress and distortion can be produced by friction stir
welding, impeding industrial implementation. Finite element analysis has been
used to develop three innovative rolling methods that reduce residual stress and
distortion in friction stir welds. Of the three methods, post-weld direct
rolling where a single roller is applied to roll the top surface of the weld
after the weld metal has cooled to room temperature proved the most effective.
The residual stress predictions from the model compared favourably with residual
stress measurements reported in an accompanying paper. Finally, the
effectiveness of using post-weld direct rolling is illustrated with an
industrial example of a large integrally stiffened panel, where the distortion
was virtually eliminated
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