Academic literature on the topic 'Aerospace friction stir welded components'
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Journal articles on the topic "Aerospace friction stir welded components"
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Bach, Michael, Ali Merati, and Michael Gharghouri. "Effects of Fatigue on the Integrity of a Friction Stir Welded Lap Joint Containing Residual Stresses." Advanced Materials Research 996 (August 2014): 794–800. http://dx.doi.org/10.4028/www.scientific.net/amr.996.794.
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This research uses a non-destructive method of neutron diffraction to measure the tri-axial residual stresses in a friction stir welded aerospace fuselage component: a stringer-to-skin lap joint. Two different specimens were examined. Fatigue testing was performed on both specimens to determine their fatigue lives. Effects of the different components of residual stresses were examines and related to fatigue performance. A combination of fractography, hardness testing, and residual stress measurement was used to predict areas of high probability of structural failure in the friction stir welded lap joints.
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Jung, Hyun Ho, Ye Rim Lee, Jong Hoon Yoon, Joon Tae Yoo, Kyung Ju Min, and Ho Sung Lee. "Solid State Welding Process for Aerospace Components." Advanced Materials Research 1119 (July 2015): 597–600. http://dx.doi.org/10.4028/www.scientific.net/amr.1119.597.
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Since solid state welded joint is formed from an intimate contact between two metals at temperatures below the melting point of the base materials, the structural integrity of welding depends on time, temperature, and pressure. This paper provides some of examples of friction stir welding and diffusion welding process for aerospace components. Friction stir welding process of AA2195 was developed in order to study possible application for a large fuel tank. Massive diffusion welding of multiple titanium sheets was performed and successful results were obtained. Diffusion welding of dissimilar metals of copper and stainless steel was necessary to manufacture a scaled combustion chamber. Diffusion welding of copper and steel was performed and it is shown that the optimum condition of diffusion welding is 7MPa at 890°C, for one hour. It is shown that solid state welding processes can be successfully applied to fabricate lightweight aerospace parts.
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Pakkanen, Jukka, Andreas Huetter, Cecilia Poletti, Norbert Enzinger, Christof Sommitsch, and Ji Tai Niu. "Friction Stir Welding of Aluminum Metal Matrix Composite Containers for Electric Components." Key Engineering Materials 611-612 (May 2014): 1445–51. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.1445.
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For aerospace applications, light-weight boxes to protect and carry electronic equipment need to be sealed. The main requirements on the components are low thermal expansion and gas tightness. The common material for such an application is a metal matrix composite (MMC). The MMC suggested here consists of A356 aluminum alloy matrix with 15 vol.% SiC particle reinforcement. A safe limit for the electronic component inside the boxes during sealing is determined to be 180°C. Due to the boundary conditions gas tightness and low heat input, Friction Stir Welding (FSW) might be an alternative to the employed joining techniques. For the FSW process the T-Joint is the most appropriate joint geometry in respect to the box design. The geometry of the lid has to ensure the backing system for the stir zone inside the box. A successful welding of the box was done after a joint geometry optimization. The examination of the welded box concerns material characterization with microscopic methods, measuring thermal expansion in base material and stir zone and temperature measurement while FSW.
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Britto Joseph, G., G. Murugesan, R. Prabhaharan, and Tariq Mohammad Choudhury. "Investigations on the Effect of Tool Geometries on Friction Stir Welded 5052 H32 Aluminium Alloy." Applied Mechanics and Materials 766-767 (June 2015): 712–20. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.712.
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Aluminium alloys are widely used in automotive, aerospace and ship industries as high strength-to-weight ratio materials. With the increasing demand for lightweight components, their application is becoming more extensive. To study the effect of Tool geometries on Metallurgical & mechanical properties of Aluminum alloy 5052 H32 using friction stir welding process. To briefly discuss about the conditions & conclude the suitable condition for Aluminium alloy 5052 H32. To plot and conclude the hardness values for various conditions. The tool material Mild Steel IS 2062 FE410 cone type and thread type has been selected for this research for various speeds to find suitable condition. The micro structure and macro structure have checking the structural formation of welded area in details to know it the strength of the joining. The present friction stir welding research is implementing the new tools for the current issues; here we try to implement new material for already available tools.
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Praveen Raj Navukkarasan, A., K. Shanmuga Sundaram, C. Chandrasekhara Sastry, and M. A. Muthu Manickam. "Experimental Investigation of Dry and Cryogenic Friction Stir Welding of AA7075 Aluminium Alloy." Advances in Materials Science and Engineering 2021 (September 21, 2021): 1–21. http://dx.doi.org/10.1155/2021/9961590.
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An attempt has been made to investigate dry and cryogenic friction stir welding of AA 7075 aluminium alloy, which is predominantly availed in aerospace and defence component industries. These industries avail friction stir welding for joining two nonferrous materials, and minimal deviations and maximum strength are the preliminary and long time goal. A cryogenic friction stir welding setup was developed to conduct the joining of two aluminium alloy pipes. An increase of 0.76–42.93% and 3.79–31.24% in microhardness and tensile strength, respectively, is ascertained in cryogenic friction stir welding in correlation to dry friction stir welding of aluminium alloys. TOPSIS evaluation for the experimental run indicated tool profile stepped type, pipe rotation speed of 1000 rpm, welding speed of 50 mm/min, and axial force of 8 kN as close to unity ideal solution for dry and cryogenic friction stir welding of AA 7075 aluminium alloys. The friction stir-welded component under the cryogenic environment showcased drop in temperature, curtailed surface roughness, and fine grain structure owing to reduction in temperature differential occurring at the weld zone. A curtailment of 50.84% is ascertained in the roughness value for cryogenic friction stir welding in correlation to dry friction stir welding of AA 7075 alloy. A decrement of 21.68% is observed in the grain size in the cryogenic condition with correlation to the dry FSW process, indicating a drop in the coarse structure. With the curtailment of grain size and drop in temperature differential, compressive residual factor and corrosion resistance attenuated by 40.14% and 67.17% in the cryogenic FSW process in correlation to the dry FSW process, respectively.
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Rajesh, Pinnavasal Venukrishnan, Krishna Kumar Gupta, Robert Čep, Manickam Ramachandran, Karel Kouřil, and Kanak Kalita. "Optimizing Friction Stir Welding of Dissimilar Grades of Aluminum Alloy Using WASPAS." Materials 15, no. 5 (February 24, 2022): 1715. http://dx.doi.org/10.3390/ma15051715.
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Aluminum is a widely popular material due to its low cost, low weight, good formability and capability to be machined easily. When a non-metal such as ceramic is added to aluminum alloy, it forms a composite. Metal Matrix Composites (MMCs) are emerging as alternatives to conventional metals due to their ability to withstand heavy load, excellent resistance to corrosion and wear, and comparatively high hardness and toughness. Aluminum Matrix Composites (AMCs), the most popular category in MMCs, have innumerable applications in various fields such as scientific research, structural, automobile, marine, aerospace, domestic and construction. Their attractive properties such as high strength-to-weight ratio, high hardness, high impact strength and superior tribological behavior enable them to be used in automobile components, aviation structures and parts of ships. Thus, in this research work an attempt has been made to fabricate Aluminum Alloys and Aluminum Matrix Composites (AMCs) using the popular synthesis technique called stir casting and join them by friction stir welding (FSW). Dissimilar grades of aluminum alloy, i.e., Al 6061 and Al 1100, are used for the experimental work. Alumina and Silicon Carbide are used as reinforcement with the aluminum matrix. Mechanical and corrosion properties are experimentally evaluated. The FSW process is analyzed by experimentally comparing the welded alloys and welded composites. Finally, the best suitable FSW combination is selected with the help of a Multi-Attribute Decision Making (MADM)-based numerical optimization technique called Weighted Aggregated Sum Product Assessment (WASPAS).
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Moreira, Pedro Miguel Guimarães Pires, and Paulo Manuel Salgado Tavares de Castro. "Fatigue Crack Growth on FSW AA2024-T3 Aluminum Joints." Key Engineering Materials 498 (January 2012): 126–38. http://dx.doi.org/10.4028/www.scientific.net/kem.498.126.
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Friction stir welding (FSW) is a solid-state joining process which emerged as an alternative technology to join high strength alloys that were difficult to weld with conventional techniques, [1]. Developments of this technique are being driven by aeronautic, aerospace and railway industries. An advantage of this joining technique is its low heat input when compared with arc welding processes. This feature allows the achievement of high mechanical properties, low distortion and low residual stresses, [2]. Also, since it is a solid-state welding process, hydrogen cracking or heat affected zone (HAZ) softening phenomena are limited. This paper presents a study of fatigue crack growth behaviour of friction stir welded butt joints of AA2024-T3, aluminium commonly used in riveted aeronautic fuselage structures. Crack growth studies are often carried out using uniform thickness joints, ASTM E647 [3]. Nevertheless, for some applications there is a need to join components with different thicknesses, which, under certain limits, can be welded using FSW. Crack growth tests on these joints are not standard. The present study concerns butt joints made using two plates with different thicknesses, 3.8mm and 4.0mm. The joints’ mechanical behaviour was studied performing static (tensile) and fatigue tests. The fatigue crack growth rate of cracks growing in different zones of the welded joint (nugget, heat affected zone - HAZ) and in base material was analysed. The microhardness profile was assessed in order to analyse the influence of the welding process in each weld zone. Further to higher static properties, welded joints present lower crack growth rate when compared with its base material.
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Ahmed, Mohamed M. Z., Mohamed M. El-Sayed Seleman, Ibrahim Albaijan, and Ali Abd El-Aty. "Microstructure, Texture, and Mechanical Properties of Friction Stir Spot-Welded AA5052-H32: Influence of Tool Rotation Rate." Materials 16, no. 9 (April 27, 2023): 3423. http://dx.doi.org/10.3390/ma16093423.
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Friction stir spot welding (FSSW) of similar AA5052-H32 joints has numerous benefits in shipbuilding, aerospace, and automotive structural applications. In addition, studying the role of tool rotation speed on the microstructure features, achieved textures, and joint performance of the friction stir spot-welded (FSSWed) joint still needs more systematic research. Different FSSWed AA5052-H32 lap joints of 4 mm thickness were produced at different heat inputs using three tool rotation speeds of 1500, 1000, and 500 rpm at a constant dwell time of 2 s. The applied thermal heat inputs for achieving the FSSW processes were calculated. The produced joints were characterized by their appearance, macrostructures, microstructures, and mechanical properties (hardness contour maps and maximum tensile–shear load) at room temperature. The grain structure and texture developed for all the FSSWed joints were deeply investigated using an advanced electron backscattering diffraction (EBSD) technique and compared with the base material (BM). The main results showed that the average hardness value of the stir zone (SZ) in the welded joints is higher than that in the AA5052-H32 BM for all applied rotation speeds, and it decreases as the rotation speed increases from 500 to 1000 rpm. This SZ enhancement in hardness compared to the BM cold-rolled grain structure is caused by the high grain refining due to the dynamic recrystallization associated with the FSSW. The average grain size values of the stir zones are 11, 9, and 4 µm for the FSSWed joints processed at 1500, 1000, and 500 rpm, respectively, while the BM average grain size is 40 µm. The simple shear texture with B/-B components mainly dominates the texture. Compared to the welded joints, the joint processed at 500 rpm and a 2 s duration time attains the highest tensile-shear load value of 4330 N. This value decreases with increasing rotation speed to reach 2569 N at a rotation speed of 1500. After tensile testing of the FSSWed joints, the fracture surface was also examined and discussed.
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Buffa, Gianluca, and Livan Fratini. "Computer Aided Design of an Effective Fixture for FSW Processes of Titanium Alloys." Key Engineering Materials 473 (March 2011): 304–9. http://dx.doi.org/10.4028/www.scientific.net/kem.473.304.
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During the last years welded titanium components have been extensively applied in aeronautical and aerospace industries because of their high specific strength and corrosion resistance properties. Friction Stir Welding (FSW) is a solid state welding process, currently industrially utilized for difficult to be welded or “unweldable” aluminum and magnesium alloys, able to overcome the drawbacks of traditional fusion welding techniques. When titanium alloys are concerned, additional problems arise as the need for very high strength and high temperature resistant tools, gas shield protection and high stiffness machines. Additionally, the process is characterized by an elevated sensitivity to temperature variations, which, in turn, depends on the main operative parameters. Numerical simulation represents the optimal solution in order to perform an effective process optimization with affordable costs. In this paper, a fully 3D FEM model for the FSW process is proposed, that is thermo-mechanically coupled and with rigid-viscoplastic material behavior. Experimental clamping parts are modeled and the thermal loads are calculated at the varying of the cooling strategy. Finally, the effectiveness of the cooling systems is evaluated through experimental tests.
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Mishra, Akshansh, and Devarrishi Dixit. "Friction Stir Welding of Aerospace Alloys." Journal of Mechanical Engineering 48, no. 1 (April 23, 2019): 37–46. http://dx.doi.org/10.3329/jme.v48i1.41093.
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Friction Stir Welding (FSW) is a solid state joining process which possesses a great potential to revolutionise the aerospace industries. Distinctive materials are selected as aerospace alloys to withstand higher temperature and loads. Sometimes these alloys are difficult to join by a conventional welding process but they are easily welded by FSW process. The FSW process in aerospace applications can be used for: aviation for fuel tanks, repair of faulty welds, cryogenic fuel tanks for space vehicles. Eclipse Aviation, for example, has reported dramatic production cost reductions with FSW when compared to other joining technologies. This paper will discuss about the mechanical and microstructure properties of various aerospace alloys which are joined by FSW process.
Dissertations / Theses on the topic "Aerospace friction stir welded components"
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Trahan, Patrick. "Corrosion Protection of Friction Stir Welded Al 7075 Panel for use in Aerospace Applications using Cold Gas Dynamic Spray." Thesis, Université d'Ottawa / University of Ottawa, 2014. http://hdl.handle.net/10393/30645.
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The aerospace industry is constantly looking for methods to reduce the cost of flying their airplanes. These savings can come in many forms, one of them being cost savings attributed to fuel savings by either reducing the weight of the airplane or reducing the drag. Friction stir welding (FSW) was introduced as a means of joining previously unweldable Al 7075, a high-strength aluminum alloy commonly used in aerospace for its high specific strength. This eliminated the need for costly and time consuming rivets to be installed, firstly reducing the production cost of the airplane and secondly reducing the overall weight of the airplane therefore improving fuel consumption.
There are many factors at play in the process of producing FSW Al 7075, but the result of this process creates a weld joint that is more susceptible to corrosion than the rest of the panel. For this reason, FSW Al 7075 panel fail prematurely and must be replaced too often. The main goal of this project is, using cold gas dynamic spray, to create a metallic layer on top of an Al 7075 FSW joint to protect it against corrosion.
A series of 3 corrosion tests indicated that pure Al, among coatings of pure Al, Al 5038 and Al 7075, offered the best protection against corrosion. Al 5083 would also be a suitable material and should be used in applications where high bond strengths are required. Al 7075, although of the same alloy as the parent material, is not recommended for corrosion protection as it offered little advantage over the parent material.
In order to better understand the interaction of creating a coating after a hot welding process, several analyses were performed. These included deposition at multiple substrate temperatures as well as hardness and velocity measurements. Results indicate that some aluminum alloys are very sensitive to temperature, yielding better coatings at high substrate temperatures. Individual particle deposition tests reveal that these improvements do not occur at the substrate-coating interface.
Another portion of this project was dedicated to creating tensile specimens composed entirely of pure Al cold sprayed coatings. Several sets of samples were produced. Results indicate that pulling in the direction of nozzle travel direction yields UTS values 50% higher than pulling in the direction perpendicular to the direction of nozzle travel during coating deposition. Results after annealing seem to converge towards the same value. Finally, a new nozzle design was performed which should create a more efficient spraying process, resulting in cost savings for the industry.
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Alfaro, Mercado Ulises [Verfasser]. "Microstructure, mechanical behavior and corrosion properties of friction stir welded aluminum alloys used in the aerospace industry / Ulises Alfaro Mercado." Aachen : Hochschulbibliothek der Rheinisch-Westfälischen Technischen Hochschule Aachen, 2012. http://d-nb.info/1022088807/34.
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Ragupathy, V. D. "Studies on Non-Destructive Evaluation of Friction Stir Weld Discontinuities with Probability of Detection." Thesis, 2018. https://etd.iisc.ac.in/handle/2005/5323.
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Friction stir welding(FSW) is a solid-state metal joining process which is currently being
considered for joining of aerospace components. The zones associated with FSW are distinctly
different from the fusion weld and their properties also vary. Further, the discontinuities and
defects encountered are unique in nature.
As most aerospace components are designed with limited margin, the identification of the
Friction stir weld defects and discontinuities, and their effect on the performance pose
continuous challenges for the quality assessment. Thus, detection, location and characterization
of different types of defects encountered in FSW, along with Probability of Detection (POD) of
those discontinuities in aerospace friction stir welded components with its varying metallurgical
characteristics are the primary objectives of the investigations taken up.
The focus has been on capability of different NDE tools in detecting and evaluating different
types of defects in FSW joints in the Aluminum alloy AA2219 and to establish the outcome
through POD concept.
Book chapters on the topic "Aerospace friction stir welded components"
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Baxter, S. C., and A. P. Reynolds. "Characterization of Reinforcing Particle Size Distribution in a Friction Stir Welded Al-SiC Extrusion." In Lightweight Alloys for Aerospace Application, 283–93. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2013. http://dx.doi.org/10.1002/9781118787922.ch26.
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Kalemba, Izabela, and Stanisław Dymek. "Microstructure and Properties of Friction Stir Welded Aluminum Alloys." In Encyclopedia of Aluminum and Its Alloys. Boca Raton: CRC Press, 2019. http://dx.doi.org/10.1201/9781351045636-140000425.
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Aluminium alloy 7136 belongs to the Al–Zn–Mg–Cu group of aluminium alloys strengthened by precipitation. These alloys offer very good properties, i.e. high strength combined with good corrosion resistance, which makes them suitable for aerospace applications. The limited range of applications of these alloys is due to problems associated with their welding. The Al–Zn–Mg–Cu alloys are classified as non-weldable. The aim of this study was to determine the quality and properties of friction stir welded (FSW) joints of alloy 7136-T76. This article presents the results of a detailed study into the microstructure and mechanical properties of FSW welds. The paper demonstrates that the FSW method is suitable for joining Al–Zn–Mg–Cu alloys. The FSW joints are of good quality and high mechanical properties. Tests of joints created at various tool rotation speeds have shown that joints of suitable quality, in terms of microstructure and properties, can be obtained for a relatively wide range of process parameters. The tool rotation speeds applied during the welding process did not have a significant influence on the quality of the welds.
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R., Radha, Sreekanth D., Tushar Bohra, and Surya Bhan Pratap Singh. "Mechanical and Corrosion Behavior of Friction Stir Welded AA 6063 Alloy." In Handbook of Research on Advancements in the Processing, Characterization, and Application of Lightweight Materials, 206–14. IGI Global, 2022. http://dx.doi.org/10.4018/978-1-7998-7864-3.ch010.
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Friction stir welding (FSW) is considered to be the most significant development in solid state metal joining processes. This joining technique is energy efficient, environmentally friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. The project aims to join Aluminum 6063 alloy plates by FSW and emphasize the (1) mechanisms responsible for the formation of welds without any defects, microstructural refinement, and (2) effects of FSW parameters on resultant microstructure, mechanical, and corrosion properties.
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Thilagham, K. T., and S. Muthukumaran. "Center Stir Zone Investigations of Dissimilar AA6082, AA2014 and AA7075 Welds." In Welding Principles and Application [Working Title]. IntechOpen, 2022. http://dx.doi.org/10.5772/intechopen.102652.
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The study compares the mechanical and metallurgical properties of AA6082, AA2014, and AA7075 dissimilar friction stir welded aluminum 6 mm plates. The alloys AA2014 and AA7075 are aerospace grade, whereas AA6082 is structural grade. The AA6082/AA7075, AA6082/AA2014, and AA2014/AA7075 joints were formed with optimized parameters of 2° tilt angle, 900 rpm rotational speed, and 80 mm/min feed rate with a constant axial force of 20 kN. Then, to investigate the stir zone properties of the joints, the tensile strength, microstructural, and hardness variations across the weld were revealed. Despite the fact that the strength of each joint was varied, the fine grain in the stir zone across the weld and advancing side weld/HAZ failure in tensile failure were studied for all welds. Further EBSD analysis revealed fine grains for the formation of its center stir zone due to dynamic recovery recrystallization during welding.
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Shaik, Bazani, Gosala Harinath Gowd, and Bandaru Durga Prasad. "Investigations on Friction Stir Welding to Improve Aluminum Alloys." In Liquid Metals. IntechOpen, 2021. http://dx.doi.org/10.5772/intechopen.96250.
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Today is an era of metals including Aluminum alloys owing to a fundamental paradigm shift in research objectives. In addition to superior performance and lightweight criteria that are used to define the innovations of yore, scientists today are compelled to take into consideration the environment-friendliness of the new and novel materials being developed due to the concerns of maintaining a sustainable and safe existence. The solid-state Friction stir welding process has immense potential in the areas of automobiles, aerospace and construction industries due to its overwhelming advantages over the conventional fusion welding process of aluminum alloys. The thesis presents an experimental investigation of friction stir welding of dissimilar aluminum alloys AA7075T651 and AA6082T651. Mathematical modeling equations are developed to predict the tensile strength, impact strength, elongation, and micro-hardness of the dissimilar FSW joints AA7075T651 and AA6082T651. The process parameters are optimized for maximum tensile strength and hardness values. Post weld heat treatment is conducted and the metallurgical properties of the FS welded AA7075T651 and AA6082T651 are presented for different combinations of tool rotational speeds. Aluminum and its alloys are widely used in nonferrous alloys for many industrial applications. Aluminum exhibits a combination of an excellent mechanical strength with lightweight and thus it is steadily replacing steel in industrial applications where the strength to weight ratio plays a significant role. In conventional welding, the joining of aluminum is mainly associated with a high coefficient of thermal expansion, solidification shrinkage and dissolution of harmful gases in the molten metal during welding. The weld joints are also associated with segregation of secondary alloys and porosities which are detrimental to the joint qualities. Friction Stir Welding (FSW) and Friction Welding (FW) are the most popular emerging solid welding techniques in aircraft and shipbuilding industries. FSW is mainly used for the joining of metal plates and FW is mainly used for the joining of rods. Both techniques are suitable for high strength material having less weight. These techniques are environmentally friendly and easy to execute. Hence, the study of these techniques can contribute much to the field of green technology. This research work is dealt with the experimental and numerical investigations on FSW and FW of aluminum alloys.
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Nakai, M., M. Niinomi, J. Hieda, K. Cho, K. Komine, H. Fujii, Y. Morisada, et al. "Microstructure and fatigue properties of double-sided friction stir welded Ti-4.5Al-2.5Cr-1.2Fe-0.1C alloy plate for aerospace applications." In Proceedings of the 1st International Joint Symposium on Joining and Welding, 429–34. Elsevier, 2013. http://dx.doi.org/10.1533/978-1-78242-164-1.429.
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Melhem, George Nadim. "Aerospace Fasteners: Use in Structural Applications." In Encyclopedia of Aluminum and Its Alloys. Boca Raton: CRC Press, 2019. http://dx.doi.org/10.1201/9781351045636-140000240.
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Aircraft components need to be selected and manufactured to adequately combat the environment, temperature, loading, compatibility, and so on. When structural materials such as aluminum alloys or fiber-reinforced polymer composites need to be joined in aircraft, the selection of fasteners, bolts, rivets, adhesives, and other methods need to be quantitatively assessed in order that the correct design for the component and joining method is identified. There is a variety of fasteners, bolts, and rivets, made using a variety of materials. Aluminum rivets are often used to join aluminum components in an aircraft. Rivets do not perform well under tension loading, but perform better in shear, thus limiting the application specifically for these purposes. Bolts are designed to clamp material together, and even though the bolt may be adequate to support a particular structure and load requirement, consideration must also be given to the modulus of elasticity and stiffness of the components that are being clamped together. Therefore, an understanding of each of the materials being clamped or joined together is necessary. Bolts manufactured from steel, for instance, have coatings applied in order to help protect them from corrosion. The use of composites translates to a reduced number of rivets and fasteners to be used. Drilling of holes into composites to insert fasteners poses many challenges because the fibers are damaged, a region of high stress concentration may be formed, and the hole is a site for the ingress of water or moisture. The insertion of aluminum fasteners or the contact of aluminum components with carbon fibers creates galvanic corrosion due to the large difference in electrical potential. Titanium alloy (Ti-6Al-4V) is a typical fastener where there is composite joining due to its better compatibility (elimination of galvanic corrosion) and increased strength properties. Substitution of rivets and fasteners for welding is also on the increase in aircraft because laser beam welding (LBW) and friction stir welding both reduce cracking, porosity, and better properties achieved due to deeper penetration, and reduce the heat-affected zone which would typically be undesirable with conventional arc welding such as metal inert gas and tungsten inert gas welding. The shear and compressive stresses are increased, and fatigue cracking, weight, and cost are also reduced as a result of LBW, including the elimination of stresses and corrosion associated with rivets and the elimination of adhesives. Dissimilar metals such as the 7000 series and the 2000 series can be joined with a filler metal compatible to both metals to mitigate galvanic corrosion.
Conference papers on the topic "Aerospace friction stir welded components"
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García Ruano, Shirley Alexandra, Felipe Bertelli, and Auteliano Antunes dos Santos. "Evaluation of 7050 Aluminum Plates Joined by Friction Stir Welding Using Acoustoelastic." In ASME 2017 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/imece2017-71668.
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The 7050-T7451 aluminum alloy has been widely used in the aerospace industry. Due to its chemical composition, this alloy has high levels of mechanical properties that allow the production of low-weight aircraft structural components. However, these alloys are thermally treatable and are not able to bear manufacturing processes involving heat. Because of the importance of their applications, studies based on the development of solid state welding process would be desirable aiming to find an alternative to generate welded joints for this kind of components. In this work, an investigation concerning the behavior of the 7050-T7451 aluminum alloy during Friction Stir Welding (FSW) was carried out. The profile of longitudinal residual stresses of plates welded by the FSW process was obtained using the ultrasonic method through critically refracted longitudinal waves (LCR). Two different frequencies were employed, 3.5 MHz and 5 MHz. The measurements were performed in the longitudinal direction of the welded joint at different distances from the center line of the weld. The magnitude and distribution of residual stresses found with this method are consistent with literature review, reaching 150MPa on the center of the weld.
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Ashwath, P., M. Anthony Xavior, P. Jeyapandiarajan, and J. Joel. "Influence of In-Process Cryogenic Cooling on Mechanical Performance of Friction Stir T6 – AA 2900 Alloy Weldments." In ASME 2021 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/imece2021-68033.
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Abstract Al-Li-Cu alloy A12195-T84 is used extensively in the aerospace launch vehicle external fuel tank structures. Aerospace components are generally joined using aluminium alloy materials, which increases the overall payload capacity of the launch vehicle. In this context, friction stir welding (FSW) process could be a potential solution. In this research work, Al2900-T6 specimens hot extruded were welded by FSW, using different parametric combinations of tool rotation and welding speed. In process cryo cooling was employed to dissipate the heat generated during the FSW. Microstructure and mechanical properties of the weldments were examined for both in-process cryo cooling and normally cooled conditions. It was observed that the grain size of the nugget zone (NZ) got refined because of the in-process cryogenic cooling during FSW. It was also discovered that microhardness was more in case of in-process cryo-cooled weldments as compared to naturally cooled weldments. Micro-hardness of the NZ was observed to be highest due to formation of finer grains because of the in-process cryogenic cooling. In-process cryogenic cooling has also improved tensile properties such as yield strength and % elongation of the FSW weldments.
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Mantegh, Iraj. "Thermal Modeling for Control of Friction Stir Welding Process in Automated Manufacturing." In ASME 2011 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. ASMEDC, 2011. http://dx.doi.org/10.1115/detc2011-48774.
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Friction stir welding is a patented joining process invented in 1991 at The Welding Institute in Cambridge, UK, and further developed to the stage suitable for production. In this process, a wear resistant rotating tool is used to join sheet and plate with different materials such as aluminum, copper, lead, magnesium, zinc, and titanium. This work studies the thermal characteristics of this process and provides a modeling technique based on Neural Network that can be used for real-time control. A thermal feed-back control method is presented to control the process. Using some thermal modeling for the heat distribution during friction stir welding process, this paper displays the complexity of obtaining an accurate design for the thermal feed back control. A three-dimensional transient heat transfer model is developed here for a sequential joining process (Friction Stir Welding-FSW) applied on aluminum parts. A neural network is created based on a set of experiments to predict the spatial and temporal variations in the temperature over the weld seam for different set of input variables. The model includes the dynamic and friction behavior of the rotating spindle and the thermal behaviors of the weld components involved. The significance of this modeling approach is that it captures the movement of the spindle, simulating a sequential joining process along a continuous weld seam. The modeling results are compared with experimental data obtained by thermocouples and infrared camera, and accurately predict the trend of variations in weld temperature. A fuzzy-logic based controller is proposed to regulate the FSW process parameters to maintain the weld temperature within the margin required to ensure the weld quality. This modeling and control system can have applications in manufacturing aluminum parts in automotive and aerospace industry.
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Sidle, B. C. "Micromechanical Simulation of Deformation of Friction Stir Welded Components." In MATERIALS PROCESSING AND DESIGN: Modeling, Simulation and Applications - NUMIFORM 2004 - Proceedings of the 8th International Conference on Numerical Methods in Industrial Forming Processes. AIP, 2004. http://dx.doi.org/10.1063/1.1766501.
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Ambrogio, G., L. Fratini, and F. Micari. "Incremental Forming of Friction Stir Welded Taylored Sheets." In ASME 8th Biennial Conference on Engineering Systems Design and Analysis. ASMEDC, 2006. http://dx.doi.org/10.1115/esda2006-95375.
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In the last decade sheet metal forming market has undergone substantial mutations since the development of more efficient strategies in terms of flexibility and cost reduction is strictly due. Such requirements are not consistent with traditional metal stamping processes which are characterized by complex equipment, capital and tooling costs; thus the industrial application of such processes is economically convenient just for large scale productions. For this reason most of the research work developed in the last years has been focused on the development of new sheet forming processes able to achieve the above discussed goals. Contemporary, with particular reference to the automotive industries the requirement of light components and the engineering of the outer skin parts of the vehicles have determined the growing utilization of tailored blanks characterized by either different material or different sheet thickness. In the paper SPIF processes of FS welded aluminium blanks are investigated in order to analyse the product properties in terms of strength and formability. A proper experimental investigation has been carried out and interesting guidelines have been highlighted in the next paragraphs.
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Fakih, Mohammad Ali, Samir Mustapha, Jaafar Tarraf, Georges Ayoub, and Ramsey Hamade. "Detection and assessment of flaws in friction stir welded metallic plates." In Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems, edited by Jerome P. Lynch. SPIE, 2017. http://dx.doi.org/10.1117/12.2258701.
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Hamilton, Carter, Stanisław Dymek, and Marek Blicharski. "Friction Stir Welding of Aluminum 7136-T76511 Extrusions for Aerospace Applications." In ASME 2007 International Mechanical Engineering Congress and Exposition. ASMEDC, 2007. http://dx.doi.org/10.1115/imece2007-41154.
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This research program evaluates the residual properties of 7136-T76511 aluminum extrusions joined through friction stir welding (FSW). AA 7136 is a new aluminum alloy developed by Universal Alloy Corporation for high strength aerospace applications that also demand good corrosion resistance, such as those on the Boeing 787 or the Airbus A380. Mechanical and corrosion testing were performed on the baseline material and on panels friction stir welded at 175, 225, 250, 300, 350 and 400 RPM (all other welding parameters were held constant). Mechanical test results demonstrate that the highest joint efficiency, 74%, is achieved at 350 RPM, but for each weld condition, the elongation of the welded material is significantly reduced, 50 – 75%, from the baseline value. Fracture of the tensile specimens consistently occurred on the retreating side of the weld along the interface between the heat affected zone (HAZ) and the thermo-mechanically affected zone (TMAZ), independent of the rotational speed. Examination of fracture surfaces through SEM revealed microvoid nucleation and coalescence around secondary phase particles in the microstructure, as well as numerous stepped or laminar facets characteristic to both the baseline and welded conditions. Exfoliation corrosion testing revealed a performance gradient across the weld with the weld nugget rating the poorest at EC and the heat affected zone rating the best at EA. Qualitative assessment of corrosion resistance is supported by mass loss calculations between the baseline and welded conditions.
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Wahab, Muhammad A., and Vinay Raghuram. "Fatigue Modeling of Friction-Stir-Welded (FSW) Butt-Joints for Aerospace Applications." In ASME 2019 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/imece2019-11723.
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Abstract Among the recent research Friction-Stir-Welding (FSW) has been adopted worldwide as one of the dominant processes for welding lightweight aerospace Aluminum alloys. Al-2195 which is one of the new generation Aluminum alloys has been used in the external tank of the space shuttles. Aerospace fabricators are continuously pursuing FSW-technologies in its efforts to advance fabrication of the external tanks of the space shuttles. The future launch vehicles with reusable mandates require the structures to have excellent fatigue properties and improved fatigue lives. The butt-welded specimens of Al-2195 and Al-2219 are fatigue tested according to ASTM-E647. The effects of stress ratios, use of corrosion preventive compound (CPC), and the applications of periodic overloading on fatigue lives are investigated in this study. Scanning-electron-microscopy (SEM) is used to examine the criticality of the failure surfaces and the different modes of crack propagation that could have been initiated into the materials. It is found that fatigue life increases with the increase in stress ratio, and results show an increase in fatigue life ranging over 30% with the use of CPC, and the fatigue life increases even further with periodic overloading; whereas crack-closure phenomenon predominates the fatigue fracture. Fracture mechanics analysis and crack similitude was modified for fatigue cracks by Paris. Numerical studies using FEA has produced a model for fatigue life prediction scheme for these structures, where a novel strategy of the interface element technique with critical bonding strength criterion for formation of new fracture surfaces has been used to model fatigue crack propagation lives. The linear elastic fracture mechanics stress intensity factor is calculated using FEA and the fatigue life predictions made using this method are within 10–20% of the experimental fatigue life data obtained. This method overcomes the limitation of the traditional node-release scheme and closely matches the physics of the crack propagation.
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Bachmann, Maximilian, Johannes Stöckl PhD, Kim Rouven Riedmüller PhD, and Mathias Liewald. "Lightweight Potential and Crash Performance of Friction Stir Welded Tailored Blanks." In 23rd Stuttgart International Symposium. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 2023. http://dx.doi.org/10.4271/2023-01-1220.
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<div class="section abstract"><div class="htmlview paragraph">Previous research papers presented methods for joining different aluminium or steel sheets of the same thickness using the friction stir welding process with flat tools. A novel variant of the friction stir welding process has been developed by the Materials Testing Institute of the University of Stuttgart, enabling the joining of aluminium and steel sheets of different thicknesses in order to further increase the lightweight potential of sheet metal components. Compared to the conventional welding method, the difference of this method relates to the stir welding tool used, which consists of a stepped welding pin and allows combined lap-and-butt joints to be produced. In this context, this paper aims to demonstrate the lightweight potential and the crash performance of Tailor Welded Blanks (TWBs) made from DX54(1 mm) and AL6016 - T4 (2 mm). For this purpose, the first step was to identify possible parts of car body structures that could be replaced by components made from these TWBs. Subsequently, these parts were constructively integrated into the selected structures, which were finally used to perform crash simulations with front and side impacts. To demonstrate the benefits of the new joining technology, the calculated crash results were compared with those of the conventional car body structures and the advantages of the used TWBs were highlighted. Concretely, the friction stir welded TWBs enabled the vehicle weight to be reduced while providing comparable properties to those of currently used components, thus lowering CO<sub>2</sub> emissions during car use.</div></div>
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Sabry, Ibrahim, Abdel-Hamid I. Mourad, and Dinu Thomas Thekkuden. "Study on Underwater Friction Stir Welded AA 2024-T3 Pipes Using Machine Learning Algorithms." In ASME 2021 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/imece2021-71378.
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Abstract Underwater friction stir welding, a new variant of friction stir welding process in which the weld coupons and tool-specimen interface are completely immersed in the water, has been successful to achieve wide popularity among researchers recently. In most of the studies, the underwater friction stir welding process is limited to join the flat plates. The research conducted on the underwater friction stir welding of pipes is rare due to the complexity in the design of the fixture and setup. Therefore, the current research is aimed to investigate the scope of underwater friction stir welding process for producing quality welded pipe joints. Initially, the current research focused on developing a system with proper components and fixture attached to the vertical milling machine for underwater friction stir welding of pipes. Twenty-seven experiment runs with three intermittent levels of process parameters — spindle speed of milling machine (1000 rpm, 1400 rpm, 1800 rpm), travel speed (10 mm/min, 16 mm/min, 20 mm/min) and shoulder diameter of tool (10 mm, 15 mm, 20 mm) are designed. Secondly, Al 2024-T3 pipes having an outer diameter of 30 mm and a thickness of 3 mm are welded using an underwater friction stir welding process for every combination of the process parameter. The elongation percentage, yield strength and tensile strength are experimentally evaluated from the tensile tests. Finally, the prediction capability of machine learning algorithms such as artificial neural network (ANN), adaptive neuro-fuzzy inference system (ANFIS) and adaptive neuro-fuzzy inference system with Harris hawks optimization (ANFIS-HHO) for 70% training data and 30% testing data was evaluated. The prediction capability of the machine learning algorithms was evaluated using the Mean Absolute Error, R2 statistic and Root Mean Square Error. ANN was found to the best with the highest R2 and least RMSE for predicting all three responses. Though the ANFIS exhibited the highest R2 and highest RMSE for every response, the incorporation of Harris hawks optimization to the ANFIS slightly improved the prediction capability of ANFIS. The prediction accuracy for elongation percentage, yield strength and tensile strength is found to be in the increasing order of ANFIS, ANFIS-HHO and ANN. The underwater friction stir welding process, machine learning algorithms, methods and results discussed in the paper are promising and useful for experts in the industries.