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RESURGAM Open Day: Developments in the FSW of Steel

Seminars 11 October 2022

As part of the EU-funded RESURGAM project, TWI has been working closely with a number of partners to develop tools and techniques for the friction stir welding of steel on behalf of the shipbuilding, repair and marine construction industries.

This Open Day will provide further information on the latest technical developments in steel FSW, discuss a number of application cases and provide an opportunity to view a demonstration of steel FSW in TWI’s laboratory.

Please note that spaces for this event are limited. 


Jonathan Martin - Section Manager - Friction Welding and Processing

Jonathan Martin

Section Manager - Friction Welding and Processing

Jonathan, who is a metallurgist by training and a Fellow of The Welding Institute, joined TWI in 2005 and has more than 20 years’ of experience in friction stir welding (FSW) activities. Over the years, he has gained experience in all aspects of FSW including participating in FSW standard working groups, developing FSW training courses and delivering engineering solutions across the world. Since 2008, he has run the International Symposium on Friction Stir Welding and has published/presented over 40 scientific research reports and papers.

Stephen Cater FRIN MEI ARINA AWeldI - Principal Project Leader – Friction Welding and Processing

Stephen Cater FRIN MEI ARINA AWeldI

Principal Project Leader – Friction Welding and Processing

Stephen Cater is a Principal Project Leader at TWI’s Yorkshire Technology Centre, responsible for research into the friction stir welding (FSW) of both thick section light metal alloys such as aluminium and magnesium, and high plasticisation point materials such as steel, titanium and nickel based alloys.

A metallurgist by training, and winner of the Richard Weck Award for his work on steel, Stephen led TWI’s Core Research Programme (CRP) into the development of FSW for steel, and also led the welding elements of projects looking at FSW for marine construction. These programmes were HILDA (High Integrity Low Distortion Assembly), MOSAIC (Materials Onboard: Steel Advancements and Integrated Composites) and RESURGAM ( Robotic Survey, Repair & Agile Manufacture). Stephen also developed the capability to friction stir weld steel under oil in the FSWBOT programme which is currently developing a robotic system able to conduct patch repairs of defects inside live oil pipelines.

Stephen has led a number of single client projects on the welding of thick section (>25mm) aluminium for safety critical applications and is currently leading two major projects in this area. One is a CRP project investigating new tool designs and FSW techniques for thick section aluminium and the second is a Joint Industry Project (JIP) for a group of sponsors interested in the early commercialisation of these new FSW techniques. Stephen also led a SCP for a customer in the Power sector who had a requirement for high integrity aluminium FSW in cryogenic service. Stephen also leads TWI’s FSW training programme, having developed a series of FSW courses in accordance with the requirements of the ISO FSW Standard, ISO 25239:2011.

Santonu Ghosh - R&D Project Lead

Santonu Ghosh

R&D Project Lead
Element Six UK Ltd

Santonu is R&D Project Lead for strategic projects at E6’s Global Innovation Centre in Harwell, UK. For the past 7 years, he has been working as NPI lead which resulted in launching several new products and implementation of technologies related Polycrystalline Cubic Boron Nitride (PCBN) material. Santonu is responsible for developing technologies and products from TRL level 2-3 to TRL 9. He specialises in structural materials and product development. Prior to joining E6, Santonu developed a strong background in the characterisation of the microstructure and properties of ceramic and metallic materials under extreme environment. He has a PhD in Materials Engineering and a Masters in Metallurgy and published several international Journal articles and international Patents in the area of new technology and materials.  He is currently leading the initiative of developing tools for Friction Stir Welding (FSW) at Element Six.

Niels Troost - Lecturer, PhD student - Ship and Offshore Structures/Mechanical Behaviour

Niels Troost

Lecturer, PhD student - Ship and Offshore Structures/Mechanical Behaviour
TU Delft

Niels Troost is a PhD candidate at the Delft University of Technology in the Netherlands. Niels graduated in 2017 with a master’s degree in Offshore and Dredging Engineering, specialised in structural design and analysis. Before starting his PhD, Niels had a combined four years of experience working at a maritime research institute and as a structural engineer in the industry. Currently, Niels researches the mechanical behaviour of friction stir welded joints in steel, with a particular interest in fatigue behaviour.

Sara Fernandes - Project Manager

Sara Fernandes

Project Manager
EWF (European Federation for Welding, Joining and Cutting)

Sara has an MSc in Mechanical Engineering by IST and MSc in Management by ISCTE.

Over 10 years as Business Unit Manager for training and qualification activities | KAM @Industry | Quality, Safety, Environment Systems Manager | International Projects Experience since 2004 | Certified Trainer | Certified Coach.

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