Journal articles: '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.

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Mishra, Akshansh. "Local binary pattern for the evaluation of surface quality of dissimilar Friction Stir Welded Ultrafine Grained 1050 and 6061-T6 Aluminium Alloys." ADCAIJ: Advances in Distributed Computing and Artificial Intelligence Journal 9, no. 2 (June 19, 2020): 69–77. http://dx.doi.org/10.14201/adcaij2020926977.

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Friction Stir Welding process is an advanced solid-state joining process which finds application in various industries like automobiles, manufacturing, aerospace and railway firms. Input parameters like tool rotational speed, welding speed, axial force and tilt angle govern the quality of Friction Stir Welded joint. Improper selection of these parameters further leads to fabrication of the joint of bad quality resulting groove edges, flash formation and various other surface defects. In the present work, a texture based analytic machine learning algorithm known as Local Binary Pattern (LBP) is used for the extraction of texture features of the Friction Stir Welded joints which are welded at a different rotational speed. It was observed that LBP algorithm can accurately detect any irregularities present on the surface of Friction Stir Welded joint.

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Muhammad, Wali, Wilayat Hussain, Hamid Zaigham, and Nouman Zubair. "Evolution of Fatigue Crack Growth Phenomena in Friction Stir Welded AA2xxx Alloys." Key Engineering Materials 875 (February 2021): 227–37. http://dx.doi.org/10.4028/www.scientific.net/kem.875.227.

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Aluminum 2xxx alloys have been one of the primary materials for the structural applications of aerospace and transportation industry because of their performance, manufacturing and reliable inspection techniques. Welding is very important in the manufacturing process of structural parts and is now known as the most vital process in the manufacturing route. A relatively new process of joining of materials is friction stir welding process, which was invented by The Welding Institute (TWI) in the UK in 1991. The friction stir welding is mainly employed in aerospace, marine and transportation fields that have high safety requirements. The failure by fatigue is the dominant failure mode for structural weld joints. Since fatigue failure of parts accounts for 50 to 90% of all failures, it is of great significance to understand the fatigue properties of friction stir welded joints. The aim of this overview is to summarize the current research on fatigue crack growth behavior of friction stir welded AA2xxx alloys and critical attention is payed to the damage tolerance performance of friction stir welded aluminum joints that can be affected by welding process parameters, residual stress, stress ratio, environment and post weld treatments.

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Shanavas, S., and J. Edwin Raja Dhas. "Modeling and Analysis of Friction Stir Welding and Underwater Friction Stir Welding of Aluminium Alloy: A Review." Applied Mechanics and Materials 867 (July 2017): 127–33. http://dx.doi.org/10.4028/www.scientific.net/amm.867.127.

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The welding of aluminium and its alloys was a great challenge for researchers and technologists till 1991. Friction stir welding (FSW), a relatively new solid state joining process was first patented in 1991 by Thomas et. al. from ‘The welding Institute (TWI), England. Later its application found in various industries like aerospace, marine, automobile, etc. due to its high quality joints. The technique is energy efficient, ecofriendly and versatile too. In this review article, the modeling and analysis of friction stir welding and underwater friction stir welding (UFSW) of aluminium alloy are addressed. Commonly used method for modeling and analysis of welded joints such as Taguchi method and Response surface method (RSM) are considered for the review. Finally an attempt has been made to compare UFSW welded joints with FSW welded joints.

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Pfeiffer, Wulf, Eduard Reisacher, Michael Windisch, and Markus Kahnert. "The Effect of Specimen Size on Residual Stresses in Friction Stir Welded Aluminum Components." Advanced Materials Research 996 (August 2014): 445–50. http://dx.doi.org/10.4028/www.scientific.net/amr.996.445.

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Friction stir welding (FSW) is a well-known technique which allows joining of metal parts without severe distortion. Because FSW involves less heat input relative to conventional welding, it may be assumed that cutting specimens from larger friction stir welded components results in a negligible redistribution of residual stresses. The aim of the investigations was to verify these assumptions for a welded aluminum plate and a circumferentially-welded aluminum cylinder. Strain gage measurements, X-ray diffraction and the incremental hole drilling method were used.

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Mabuwa, Sipokazi, and Velaphi Msomi. "Review on Friction Stir Processed TIG and Friction Stir Welded Dissimilar Alloy Joints." Metals 10, no. 1 (January 17, 2020): 142. http://dx.doi.org/10.3390/met10010142.

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There is an increase in reducing the weight of structures through the use of aluminium alloys in different industries like aerospace, automotive, etc. This growing interest will lead towards using dissimilar aluminium alloys which will require welding. Currently, tungsten inert gas welding and friction stir welding are the well-known techniques suitable for joining dissimilar aluminium alloys. The welding of dissimilar alloys has its own dynamics which impact on the quality of the weld. This then suggests that there should be a process which can be used to improve the welds of dissimilar alloys post their production. Friction stir processing is viewed as one of the techniques that could be used to improve the mechanical properties of a material. This paper reports on the status and the advancement of friction stir welding, tungsten inert gas welding and the friction stir processing technique. It further looks at the variation use of friction stir processing on tungsten inert gas and friction stir welded joints with the purpose of identifying the knowledge gap.

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Kumar, R. Ashok, and M. R. Thansekhar. "Effects of Tool Pin Profile and Tool Shoulder Diameter on the Tensile Behaviour of Friction Stir Welded Joints of Aluminium Alloys." Advanced Materials Research 984-985 (July 2014): 586–91. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.586.

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— For fabricating light weight structures, it requires high strength-to weight ratio. AA6061 aluminium alloy is widely used in the fabrication of light weight structures. A356 aluminium alloy has wide spread application in aerospace industries. Friction stir welding is solid state joining process which is conducting for joining similar and dissimilar materials. The friction stir welding parameters play an important role for deciding the strength of welded joints. In this investigation, A356 and AA6061 alloys were friction stir welded by varying triangular, square, hexagonal pin profiles of tool keeping the remaining parameters same and AA6061 alloys were friction stir welded by varying tool shoulder diameter as 12mm,15mm,18mm without changing other parameters. Tensile properties of each joint have been analyzed microscopically. From the experimental results, it is observed that hexagonal pin profiled tool and 15mm shoulder diameter tool provides higher tensile properties when compared to other tools.

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Mostaan, Hossein, Mehdi Safari, and Arash Bakhtiari. "Micro friction stir lap welding of AISI 430 ferritic stainless steel: a study on the mechanical properties, microstructure, texture and magnetic properties." Metallurgical Research & Technology 115, no. 3 (2018): 307. http://dx.doi.org/10.1051/metal/2018003.

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In this study, the effect of friction stir welding of AISI 430 (X6Cr17, material number 1.4016) ferritic stainless steel is examined. Two thin sheets with dimensions of 0.4 × 50 × 200 mm3 are joined in lap configuration. Optical microscopy and field emission electron microscopy were used in order to microstructural evaluations and fracture analysis, respectively. Tensile test and microhardness measurements are employed in order to study the mechanical behaviors of welds. Also, vibrational sample magnetometry (VSM) is employed for characterizing magnetic properties of welded samples. Texture analysis is carried out in order to clarify the change mechanism of magnetic properties in the welded area. The results show that AISI 430 sheets are successfully joined considering both, the appearance of the welding bead and the strength of the welded joint. It is found that by friction stir welding of AISI 430 sheets, texture components with easy axes magnetization have been replaced by texture components with harder magnetization axes. VSM analysis showed that friction stir welding leads to increase in residual induction (Br) and coercivity (Hc). This increase is attributed to the grain refining due the friction stir welding and formation of texture components with harder axes of magnetizations.

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Lee, Ye Rim, Kookil No, Jong Hoon Yoon, Joon Tae Yoo, and Ho Sung Lee. "Investigation of Microstructure in Friction Stir Welded Al-Cu-Li Alloy." Key Engineering Materials 705 (August 2016): 240–44. http://dx.doi.org/10.4028/www.scientific.net/kem.705.240.

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It is well known that the addition of Li to aluminum alloys offers an attractive combination of low density and high modulus, which are useful for lightweight structures of aerospace vehicles. However, microstructure of Al-Li alloys are complex, which consist of a number of equilibrium and metastable phases. In addition, Al-Li alloys are weldable but the weldability is not as good as that of other aerospace alloys. This is due to the reactive property of element Li during melting and causes porosity, cracking and low joint efficiency. In friction stir welding (FSW), rotating welding tool generates frictional heat and by keeping the tool rotating and moving speed, the heat from friction causes the plate to soften without melting. Therefore, this solid state welding is adequate to Al-Li alloys. The friction stir welded joint was divided into 9 regions and each microstructure was investigated in detail to present the microstructure evolution and material flows during friction stir welding process. The recrystallized structure is observed in nugget zone and the evidence of initiation of dynamic recrystallization is found around the boundary between thermo-mechanically affected zone (TMAZ) and nugget region. This paper describes the results of a study to investigate the microstructure change of Al-Cu-Li alloy during the friction stir welding process.

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Khan, Noor Zaman, Arshad Noor Siddiquee, Zahid A. Khan, Mohammed Ubaid, Dhruv Bajaj, Mohd Atif, and Adnan Khan. "Microstructure evolution of Friction Stir Welded Dissimilar Aerospace Aluminium Alloys." IOP Conference Series: Materials Science and Engineering 404 (September 28, 2018): 012002. http://dx.doi.org/10.1088/1757-899x/404/1/012002.

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Cojocaru, Radu, Lia Boțilă, Cristian Ciucă, Horia Florin Dascau, and Victor Verbiţchi. "Friction Stir Lap Welding of Light Alloy Sheets." Advanced Materials Research 814 (September 2013): 187–92. http://dx.doi.org/10.4028/www.scientific.net/amr.814.187.

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Aluminum alloys are widely used in aerospace, automotive, railway and shipbuilding industry, as materials having remarkable properties for applications in these fields. For this reason, in recent years the interest for friction stir lap welding of sheets from these alloys increased.The behaviour of welding materials from the plastic and mechanic viewpoint are different in case of friction stir lap welding compared to friction stir butt welding.The welding tools for friction stir lap welding can have different configurations and sizes compared to butt welding. The used welding parameters must be reconsidered in order to obtain a proper flow of material for obtaining a friction stir lap welded joint.In addition, it is very important how to prepare the sheets surfaces that come into contact and their placement (relative to each other).The paper presents considerations regarding friction stir lap welding, with examples/concrete results obtained in welding of similar and dissimilar light alloys (alloys of aluminum, magnesium and titanium). It also presents data on the characteristics of obtained welded joints, related with particularities of friction stir lap welding.The obtained results showed that light alloys sheets used in various industrial fields can be joined with respect of basis conditions specific for the friction stir lap welding process.

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Lee, Ho Sung, Jong Hoon Yoon, Joon Tae Yoo, and Kyung Ju Min. "Microstructure and Mechanical Properties of Friction Stir Welded AA2195-T0." Materials Science Forum 857 (May 2016): 266–70. http://dx.doi.org/10.4028/www.scientific.net/msf.857.266.

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Aluminum-copper-lithium alloy is a light weight metal that has been used as substitute for conventional aerospace aluminum alloys. With addition of Li element, it has lower density but higher strength. However these aluminum alloys are hard to weld by conventional fusion welding, since they often produce porosities and cracking in the weld zone. It is known that solid state welding like friction stir welding is appropriate for joining of this alloy. In this study, friction stir welding was performed on AA2195 sheets, in butt joint configuration in order to understand effects of process parameters on microstructure and mechanical properties in the weld zone. The results include the microstructural change after friction stir welding with electron microscopic analysis of precipitates.

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Li, Hongjun, Jian Gao, and Qinchuan Li. "Fatigue of Friction Stir Welded Aluminum Alloy Joints: A Review." Applied Sciences 8, no. 12 (December 14, 2018): 2626. http://dx.doi.org/10.3390/app8122626.

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The application fields of friction stir welding technology, such as aerospace and transportation, has high safety requirements and fatigue is the dominant failure mode for weldments. It is of great significance to understand the fatigue properties of friction stir welded joints. This paper provides an overview of the fatigue mechanism, influencing factors, crack growth rate, and fatigue life assessment. It is found that the fatigue performance of friction stir welded joints can be affected by welding process parameters, test environment, stress ratio, residual stress, and weld defect. The optimized process parameters can produce high quality weld and increase the weld fatigue life. Laser peening is an effective post weld treatment to decrease fatigue crack growth rate and improve material fatigue life.

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Shettigar, Arun Kumar, Subramanya Prabhu, Rashmi Malghan, Shrikantha Rao, and Mervin Herbert. "Application of Neural Network for the Prediction of Tensile Properties of Friction Stir Welded Composites." Materials Science Forum 880 (November 2016): 128–31. http://dx.doi.org/10.4028/www.scientific.net/msf.880.128.

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In this paper, an attempt has been made to apply the neural network (NN) techniques to predict the mechanical properties of friction stir welded composite materials. Nowadays, friction stri welding of composites are predominatally used in aerospace, automobile and shipbuilding applications. The welding process parameters like rotational speed, welding speed, tool pin profile and type of material play a foremost role in determining the weld strength of the base material. An error back propagation algorithm based model is developed to map the input and output relation of friction stir welded composite material. The proposed model is able to predict the joint strength with minimum error.

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Shyamlal, Chandrasekaran, Rajesh Shanmugavel, J. T. Winowlin Jappes, Anish Nair, M. Ravichandran, S. Syath Abuthakeer, Chander Prakash, Saurav Dixit, and N. I. Vatin. "Corrosion Behavior of Friction Stir Welded AA8090-T87 Aluminum Alloy." Materials 15, no. 15 (July 26, 2022): 5165. http://dx.doi.org/10.3390/ma15155165.

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Aerospace alloys with reduced wall thickness but possessing higher hardness, good tensile strength and reasonable corrosion resistance are essential in manufacturing of structures such as fuselage. In this work, friction stir welding has been carried out on such an aerospace aluminum alloy AA8090 T87 which contains 2.3% lithium. Tool rotational speed of 900 rpm and traverse speeds of 90 mm/min., 110 mm/min. are the welding parameters. Hardness analysis, surface roughness analysis and corrosion analysis are conducted to analyze the suitability of the joint for the intended application. The samples were corrosion tested in acid alkali solution and they resulted in the formation of pits of varying levels which indicate the extent of surface degradation. Hardness of the samples was measured after corrosion analysis to observe the changes. The analysis suggests that the change in tool traverse speed transformed the corrosion behavior of the joint and affected both the hardness and surface roughness which mitigated the quality of the joint.

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Sabry, Ibrahim. "Investigation of microstructure and mechanical characteristic of underwater friction stir welding for Aluminum 6061 alloy – Silicon carbide (SiC) metal matrix composite." Journal of Mechanical Engineering and Sciences 15, no. 4 (December 15, 2021): 8644–52. http://dx.doi.org/10.15282/jmes.15.4.2021.17.0683.

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Demand for metal matrix composites (MMCs) is expected to increase in these applications, such as ‎in the aerospace and automotive sectors. Adequate joining techniques, which are important for ‎structural materials, have not yet been developed for Metal Matrix Composite (MMCs), however. ‎This work aimed to demonstrate the feasibility of ‎friction stir welding (FSW) and ‎underwater friction stir welding (UFSW) for joining Al 6061/5, Al 6061/10, and Al ‎‎6061/18 wt. %SiC composites have been produced by utilizing reinforce stir casting technique. Two ‎rotational ‎speeds,1000and 1800 rpm, and traverse speed 10mm \ min were examined. Specimen ‎composite plates 10 mm thick have been successfully welded by FSW. For FSW and UFSW, a tool ‎made of high-speed steel (HSS) with a conical pin shape was used. The result revealed that the ‎ultimate tensile strength of the welded joint by FSW and UFSW at rotation speed 1800 rpm for (Al ‎‎6061/18 wt. ‎‎% SiC composites) was 195 MPa and 230 MPa respectively. The ultimate ‎tensile ‎strength of the welded joint by FSW and UFSW (Al 6061/18 wt.% SiCe composites) was 165 MPa ‎and 180 MPa at rotation speed ‎‎1000 rpm respectively. The microstructural assessment showed that due ‎to larger grain sizes at FSW and UFSW, most of the fractures are located in the thermal ‎mechanically affected zone (TMAZ) adjacent to the weld nugget zone (WNZ). It is observed that in ‎failure, most of the joints show ductile features. As the volume fraction of SiC (18 wt.%) increases, ‎the friction stir welded and underwater friction stir welded efficiency decreases.

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Azevedo, José, Virgínia Infante, Luisa Quintino, and Jorge dos Santos. "Fatigue Behaviour of Friction Stir Welded Steel Joints." Advanced Materials Research 891-892 (March 2014): 1488–93. http://dx.doi.org/10.4028/www.scientific.net/amr.891-892.1488.

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The development and application of friction stir welding (FSW) technology in steel structures in the shipbuilding industry provide an effective tool of achieving superior joint integrity especially where reliability and damage tolerance are of major concerns. Since the shipbuilding components are inevitably subjected to dynamic or cyclic stresses in services, the fatigue properties of the friction stir welded joints must be properly evaluated to ensure the safety and longevity. This research intends to fulfill a clear knowledge gap that exists nowadays and, as such, it is dedicated to the study of welded steel shipbuilding joints in GL-A36 steel, with 4 mm thick. The fatigue resistance of base material and four plates in as-welded condition (using several different parameters, tools and pre-welding conditions) were investigated. The joints culminate globally with defect-free welds, from which tensile, microhardness, and fatigue analyses were performed. The fatigue tests were carried out with a constant amplitude loading, a stress ratio of R=0.1 and frequency between 100 and 120 Hz. The experimental results show the quality of the welding process applied to steel GL-A36 which is reflected in the mechanical properties of joints tested.

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Nadikudi, Bhanodaya Kiran Babu. "Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates." International Journal of Structural Integrity 12, no. 4 (March 8, 2021): 562–68. http://dx.doi.org/10.1108/ijsi-10-2020-0097.

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PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.

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Dube, Nitesh, Prakash Rai, Kuldeep Giri, and Himanshu Kumar Sharma. "Optimisation of Process Parameters Friction Stir Welding." International Journal of Advance Research and Innovation 4, no. 1 (2016): 168–77. http://dx.doi.org/10.51976/ijari.411626.

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Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment 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 FSW parameters such as tool rotational speed, welding speed, welding tool shoulder diameter, and welded plate thickness play a major role in determining the strength of the joints. Aluminium alloys have gathered wide acceptance in the fabrication of light weight structures requiring a high strength and good corrosion resistance.

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Elatharasan, G., and V. S. Senthil Kumar. "Metallurgical Studies on the Friction Stir Welding of Dissimilar A356 and A413 Alloys." Advanced Materials Research 488-489 (March 2012): 345–49. http://dx.doi.org/10.4028/www.scientific.net/amr.488-489.345.

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Friction stir welding is a technique useful for joining aluminum alloys that are difficult to weld. In recent years, however the focuses has been on welding dissimilar aluminum alloys, and analyze their mechanical properties and micro-structural characteristics. In the present study, the less investigated welding of cast aluminum alloys is considered. Cast aluminum alloys, A356 and A413, commonly used in automotive and aerospace industries, were friction-stir welded and their mechanical properties and micro-structural characteristics were analyzed. On testing their welded region, no welding defects were observed. The welded region exhibited a maximum tensile strength of 90 N/mm2 and Vickers micro-hardness of 56.8. The micro-structural observations at the nugget region revealed a refined grain structure.

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Oosterkamp, L. D., and F. Heurtaux. "New polymorph friction-stir-welded aluminium liquid petroleum gas tank." Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering 220, no. 1 (January 2006): 27–35. http://dx.doi.org/10.1243/095440705x69605.

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Leo, Paola, and Emanuela Cerri. "Friction Stir Welding of Ti-6Al-4V Alloy." Materials Science Forum 783-786 (May 2014): 574–79. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.574.

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Titanium (Ti) and its alloys are used extensively in aerospace industry where there is a critical need for material with high strength-to–weight ratio and high elevate temperature properties. Friction stir welding (FSW) is a new solid state welding process in which a cylindrical–shouldered tool with an extended pin is rotated and gradually plunged into the joint between the workpieces to be welded. The material is frictionally heated to a temperature at which it becomes more plastic but no melting of the blanks to be welded is reached therefore the presence of defects typically observed in and close to the welding seam is strongly reduced. The final result is the improvement of the mechanical performances of the welded joints even in some materials with poor fusion weldability. In this paper the authors analyze the microstructure of FSW joints of Ti-6Al-4V processed at the same travel speed (50 mm/min) and at different rotation speed (300-500rpm). The microstructure of base material (BM) is not homogenous. It is characterized by distorted α/ β lamellar microstructure together with smashed zone of fragmented β layer and β retained grain boundary phase. The BM has been welded in the as received state, without any previous heat treatment. The microstructure of the transverse section of joints is not homogeneous. Close to the top of weld cross sections a much finer microstructure than the initial condition has been observed while in the center of the joints the microstructure is mixed and less refined.

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No, Koo Kil, Joon Tae Yoo, Jong Hoon Yoon, and Ho Sung Lee. "An Experimental Study of Process Parameters on Friction Stir Welded Aluminum Alloy 2219 Joint Properties." Applied Mechanics and Materials 863 (February 2017): 3–7. http://dx.doi.org/10.4028/www.scientific.net/amm.863.3.

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Aluminum alloy 2219 is widely used in aerospace applications since it has a unique combination of good weldability and high specific strength. Furthermore, it can provide a high strength after heat treatment with superior properties in cryogenic environment so they have been widely used for cryogenic fuel tank of space launch vehicles. It is known that solid state welding like friction stir welding can improve the joint properties of this alloy. Friction stir welding is a solid state welding technology which two materials are welded together by the frictional heat due to the rotation of the tool. In this study, friction stir welding was performed on aluminum alloy 2219 sheets. The range of welding parameter is four rotation speeds from 350 to 800 rpm and six travel speeds from 120 to 420 mm/min. The results include the microstructural change after friction stir welding. The microstructure was characterized and material in the stirred zone experience sufficient deformation and heat input which cause the complete dynamic recrystallization. The present work represents the strength at each process condition and the optimum friction stir welding process parameters. The optimum weld efficiency obtained in this study was 76.5 %.

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Gao, Zeng, Jianguang Feng, Huanyu Yang, Jukka Pakkanen, and Jitai Niu. "Friction stir welding of new electronic packaging materials SiCp/Al composite with T-joint." Engineering review 38, no. 3 (2018): 352–59. http://dx.doi.org/10.30765/er.38.3.12.

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Using friction stir welding, the electronic container box and lid made from aluminium matrix composites with reinforcement of SiC particle (15 vol% SiCp/Al-MMCs) was welded successfully with T-joint. The temperature distribution of box during the process, mechanical property and microstructure of the joint as well as gas tightness of welded box was investigated. The experimental results indicated that the satisfactory T-joint can be obtained under appropriate friction stir welding parameters. During the welding process, the bottom center, which was used to place the electronic component, reached a quite lower temperature of 100°C. That can ensure safety of components in the box. After the welding process, the microstructure in stir zone was better than in base material due to the refining and homogeneous distribution of the SiC particles. The experimental results showed that the electronic container box after friction stir welding had gas tightness. The He-leakage rate was under 10-8 Pa•m3/s.

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Lee, Ho Sung, Ye Rim Lee, and Kyung Ju Min. "Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy." Materials Science Forum 857 (May 2016): 228–31. http://dx.doi.org/10.4028/www.scientific.net/msf.857.228.

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Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

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Parasuraman, Prabhuraj, Rajakumar Selvarajan, Balasubramanian Visvalingam, Rajkumar Ilamurugan, and Kavitha Subramanian. "Stir zone stress corrosion cracking behavior of friction stir welded AA7075-T651 aluminum alloy joints." Corrosion Reviews 39, no. 1 (December 22, 2020): 55–62. http://dx.doi.org/10.1515/corrrev-2020-0065.

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Abstract AA7075 high-strength aluminum alloy, which has many applications in the aircraft, marine and automobile industries, happens to be susceptible to stress corrosion cracking (SCC) when exposed to corrosive environments, resulting in reduced service life of the components. Inappropriate fabrication processes may augment this behavior. The fabrication of AA7075 components using conventional fusion welding processes may produce defects that include hot cracking and porosity. Friction stir welding (FSW) is a solid-state joining process that can avoid these problems and being widely used for components made of aluminum alloys. Because the joining occurs at a temperature that is lower than the melting point of the material, solidification cracking defects can be eliminated. This study investigates the SCC behavior of FSW AA7075-T651 joints. Horizontal-type SCC test was conducted on circumferential-notched tensile (CNT) specimens exposed to 3.5 wt. % NaCl solutions under various axial stress conditions. The different regions of the fractured specimens, such as the machined notch, SCC region and region of ultimate mechanical failure were analyzed by scanning electron microscopy (SEM) to establish the mechanism of SCC. The threshold stress of parent metal (PM) and stir zone (SZ) of the FSW joint were found to be 242 and 175 MPa, respectively.

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Lemmen, H. J. K., R. C. Alderliesten, R. R. G. M. Pieters, R. Benedictus, and J. A. Pineault. "Yield Strength and Residual Stress Measurements on Friction-Stir-Welded Aluminum Alloys." Journal of Aircraft 47, no. 5 (September 2010): 1570–83. http://dx.doi.org/10.2514/1.c000212.

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Ma, Yu E., Bao Qi Liu, and Zhen Qiang Zhao. "Crack Paths in a Friction Stir-Welded Pad-Up for Fuselage Applications." Journal of Aircraft 50, no. 3 (May 2013): 879–85. http://dx.doi.org/10.2514/1.c032016.

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Eslami, Nima, Alexander Harms, Johann Deringer, Andreas Fricke, and Stefan Böhm. "Dissimilar Friction Stir Butt Welding of Aluminum and Copper with Cross-Section Adjustment for Current-Carrying Components." Metals 8, no. 9 (August 24, 2018): 661. http://dx.doi.org/10.3390/met8090661.

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Manufacturing dissimilar joints of aluminum and copper is a challenging task. However, friction stir welding (FSW) was found to be a suitable technique to produce aluminum–copper joints. Due to different electrical conductivities between aluminum and copper, an adjustment of the cross-section is required to realize electrical conductors free of resistive losses. Taking this into account, this paper presents initial results on the mechanical and electrical properties of friction stir butt welded aluminum and copper blanks having thicknesses of 4.7 mm and 3 mm, respectively. Three different approaches were investigated with the aim to produce sound welds with properties similar to those of the used base materials. Friction stir welding has been conducted at a welding speed of 450 mm/min. Subsequently, the welded specimens were subjected to metallographic analysis, tensile testing, and measurements of the electrical conductivity. The ultimate tensile force of the best joints was about 10 kN, which corresponds to joint efficiencies of approximately 72% of the aluminum base material. The analysis of electrical joint properties led to very promising results, so that the potential of FSW of Al–Cu butt joints with sheets having different thicknesses could be confirmed by the investigations carried out.

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Rajkumar, T., K. Radhakrishnan, C. Rajaganapathy, S. P. Jani, and Nowshadth Ummal Salmaan. "Experimental Investigation of AA6063 Welded Joints Using FSW." Advances in Materials Science and Engineering 2022 (September 19, 2022): 1–10. http://dx.doi.org/10.1155/2022/4174210.

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The AA6063 aluminium alloy has gained widespread use in manufacturing the light-weighted structures which requires a high strength to weight ratio, and it possesses an excellent corrosive resistance in T6 heat-treated (solution heat treated and artificially aged) condition. The process of friction stir welding (FSW) is an emerging joining process of solid state that does not melt and recast the material being welded, as opposed in various other fusion welding processes, which are extensively utilized for combining the structural alloys of aluminium. The process of connecting separate components with external heat has resulted in induced stress on metals. The stir welding using friction was introduced in order to reduce the formation in residual stress during the joining process. The aluminium alloy AA6063 plates were fused utilising the friction stir welding procedure in this study. The studies were carried out using various combinations of speed in rotary condition, speed in transverse condition, and stress in axial condition. The generated joints that are welded was analysed mechanically and microstructurally. The maximum hardness of the mechanical joints produced is 93.25 HV, and the maximum tensile strength is 286.15 N/mm2. According to the results of the response surface analysis, transverse and rotary velocities possess a notable impact in hardness and durability, respectively.

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Widener, Christian A., Dwight A. Burford, Brijesh Kumar, J. E. Talia, and Bryan Tweedy. "Evaluation of Post-Weld Heat Treatments to Restore the Corrosion Resistance of Friction Stir Welded Aluminum Alloy 7075-T73 vs. 7075-T6." Materials Science Forum 539-543 (March 2007): 3781–88. http://dx.doi.org/10.4028/www.scientific.net/msf.539-543.3781.

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Friction stir welding (FSW) is rapidly becoming accepted as a viable manufacturing process for aerospace applications. One potential area of concern, however, is the corrosion resistance of some FSW joints. While the corrosion resistance of friction stir welded 7075 aluminum has been investigated, and attempts made to enhance its corrosion resistance through different combinations of starting temper and post-weld artificial aging (PWAA) treatments, a clear approach for selecting pre-temper conditions and PWAA processing has not emerged. For this investigation, FSW butt-welds in sheets of 0.125-inch 7075-T73 and 7075-T6 were given a variety of PWAA treatments, some of which were developed previously by other authors. Thermal treatments were evaluated using optical microscopy, exfoliation, electrical conductivity, microhardness, tensile, and fatigue crack propagation testing. An important conclusion drawn from this work is that 7075-T73 can be friction stir welded and post-weld aged in a manner that produces superior exfoliation resistance and good mechanical properties without invalidating the bulk parent material temper specified in AMS 2770G.

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Vivas, Javier, Ana Fernández-Calvo, Egoitz Aldanondo, Uxue Irastorza, and Pedro Álvarez. "Friction Stir Weldability at High Welding Speed of Two Structural High Pressure Die Casting Aluminum Alloys." Journal of Manufacturing and Materials Processing 6, no. 6 (December 12, 2022): 160. http://dx.doi.org/10.3390/jmmp6060160.

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In this work, the friction stir weldability of two structural high-pressure die casting aluminum alloys designed to manufacture thin-walled automotive components is investigated and compared. AlSi10MnMg and AlMg4Fe2 alloys were friction stir welded at a high welding speed (from 500 to 2000 mm/min) for a fixed rotation speed of 1500 RPM. The investigation was performed by studying the material flow influence on defect formation and microstructure, the mechanical properties of the welds and the forces that act during the friction stir welding process. The AlSi10MnMg alloy shows a lower incidence of defects than the AlMg4Fe2 alloy at all welding speeds investigated. Both materials present a great friction stir welding performance at 500 mm/min with a high joint efficiency in terms of ultimate tensile strength: 92% in AlSi10MnMg alloy and 99% in AlMg4Fe2 alloy.

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Wu, Tingke, Fengqun Zhao, Haitao Luo, Haonan Wang, and Yuxin Li. "Temperature Monitoring and Material Flow Characteristics of Friction Stir Welded 2A14-t6 Aerospace Aluminum Alloy." Materials 12, no. 20 (October 17, 2019): 3387. http://dx.doi.org/10.3390/ma12203387.

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Aiming at the problems that the temperature in the welding area of friction stir welding (FSW) is difficult to measure and the joints are prone to defects. Hence, it is particularly important to study the material flow in the welding area and improve the welding quality. The temperature of the tool shoulder and the tool pin was monitored by the wireless temperature measuring system. The finite element model of friction stir welding was established and the welding conditions were numerically simulated. The flow law of material of the friction stir welding process was studied by numerical simulation. The material flow model was established by combining the microstructure analysis results, and the forming mechanism of the defects was analyzed. The results show that the temperature in the welding zone is the highest at 1300 rpm, and the temperature at the tool shoulder is significantly higher than that at the tool pin in the welding stage. When high-rotation speeds (HRS) are chosen, the material beneath the tool shoulder tends to be extruded into the pin stirred zone (PSZ) after flowing back to the advancing side. This will cause turbulence phenomenon in the advancing side of the joint, which will easily lead to the formation of welding defects. In the future, temperature monitoring methods and the flow model of material can be used to optimize the welding parameters.

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Lee, Ye Rim, Hyun Ho Jung, Jong Hoon Yoon, Joon Tae Yoo, Kyung Ju Min, and Ho Sung Lee. "A Study on Mechanical Properties of Friction Stir Welded and Electron Beam Welded AA2195 Sheets." Advanced Materials Research 1105 (May 2015): 178–81. http://dx.doi.org/10.4028/www.scientific.net/amr.1105.178.

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Aluminum-Copper-Lithium alloys are used as substitute for conventional aerospace Al alloys in cryogenic tank of liquid rocket engines, aircraft wing box and satellite systems due to their high specific modulus and specific strength. For this reason they are currently under consideration for one of the potential choices for a large structure of Korea Space Launch Vehicle. In this study, friction stir welding and electron beam welding were conducted on AA2195 sheets, in butt joint configuration in order to compare the two processes and to evaluate mechanical properties. The results provide valuable information for the optimal condition of joining AA2195 sheets for a large tankage structure of the space launcher.

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Lakshmi Balasubramaniam, Guruvignesh, Enkhsaikhan Boldsaikhan, Shintaro Fukada, Mitsuo Fujimoto, and Kenichi Kamimuki. "Effects of Refill Friction Stir Spot Weld Spacing and Edge Margin on Mechanical Properties of Multi-Spot-Welded Panels." Journal of Manufacturing and Materials Processing 4, no. 2 (June 7, 2020): 55. http://dx.doi.org/10.3390/jmmp4020055.

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Refill friction stir spot welding (RFSSW) is an emerging technology for joining aerospace aluminum alloys. The aim of the study is to investigate the effects of the refill friction stir spot weld spacing and the edge margin on the mechanical properties of multi-spot-welded AA7075-T6 panels. AA7075-T6 is a baseline aerospace aluminum alloy used in aircraft structures. The study employs an innovative robotic RFSSW system that is designed and developed by Kawasaki Heavy Industries (KHI). The experimental strategy uses Design of Experiments (DoE) to characterize the failure loads of multi-spot-welded panels in terms of the spot weld spacing, edge margin, and heat-affected zone (HAZ) of the spot weld. The RFSSW process leaves behind a thermal “imprint” as HAZ in heat-treatable aluminum alloys. According to the DoE results, larger spot weld spacings with no HAZ overlap produce higher failure loads of multi-spot-welded panels. On the other hand, edge margins that are equal to or less than the spot weld diameter demonstrate abnormal plastic deformations, such as workpiece edge swelling and weld crown dents, during the RFSSW process. The larger edge margins do not demonstrate such abnormal deformations during the welding process.

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MARTINAZZI, D., G. V. B. LEMOS, H. R. P. CARDOSO, R. E. DOS SANTOS, J. Z. FERREIRA, L. BERGMANN, J. F. DOS SANTOS, and A. REGULY. "SENSITIZATION STUDY IN FRICTION STIR WELDS OF INCONEL® 625." Periódico Tchê Química 15, no. 29 (January 20, 2018): 56–63. http://dx.doi.org/10.52571/ptq.v15.n29.2018.56_periodico29_pgs_56_63.pdf.

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The new challenges of the oil and gas industry require noble materials with chemical stability and greater mechanical properties. Alloy 625, popularly known as Inconel® 625, is used as a cladding material for pipelines and other components. Therefore, the study of joining methods that produce excellent welded joints is essential. Thus, in this study, welded sheets of Inconel 625 were produced by Friction Stir Welding (FSW) and afterwards they were subjected to a heat treatment to evaluate the susceptibility to sensitization by the Double Loop Electrochemical Potentiokinetic Reactivation(DL-EPR)technique. In addition, microhardness profiles were performed before and after the isothermal treatment. The microhardness results indicated that the increased hardness is due to the carbides formation after heat treatment. On the other hand, electrochemical tests showed that FSW process can significantly affect the degree of sensitization.

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Sabry, Ibraheem, and Ahmed M. El-Kassas. "Cost Estimation of Pipe Friction Stirs Welding." International Journal of Advance Research and Innovation 5, no. 1 (2017): 111–20. http://dx.doi.org/10.51976/ijari.511719.

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Friction stir welding was a promising welding technology from the same moment of its existence because of its easy use, being ecologically friendly processed and with no need for filler metal. The present paper discusses the cost analysis of pipe friction stir welding spicily aluminum 6061.cost estimation were performed on pipe with different thickness 2 to 4 mm. rotational speeds 485 to 1800 RPM and a travel speed 4 to 10 mm/min. The each cost component of joining Al 6061 aluminum pipe welding was each component cost (Labor cost, Power cost, Machine cost and Tooling cost) has been closely analyzed and major cost components have been included in the cost model. We used these cost models to predict the cost of friction stir welded pipe joints. Initial results show that the rotational speed, material thickness and travel speed increased due to increase the total cost. Keywords: Friction stir welding, Aluminum pipe, cost analysis

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Priya, Gupta Manoj Kumar, and Patel Vinay Kumar. "Effect of Carbonitriding on Tribomechanical and Corrosion-Resistant Properties of Friction Stir Welded Aluminium 2024 Alloy." Strojnícky časopis - Journal of Mechanical Engineering 71, no. 2 (November 1, 2021): 199–212. http://dx.doi.org/10.2478/scjme-2021-0030.

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Abstract Friction stir welding (FSW) is extensively used to join aluminium alloys components in space and aircraft industries. Al 2024 is a heat-treatable aluminium alloy with copper as the primary alloying element which has good strength and fatigue resistance. This paper investigates the effect of carbonitriding surface modification on the hardness, tensile strength and impact strength of FSW welded Al 2024 joints. The friction stir welding was performed on three different sets of aluminium alloy (Al2024:Al2024, Al2024: carbonitrided-Al2024, carbonitrided-Al2024: carbonitrided-Al2024) at two different tool rotation speed (TRS) and two welding speed using cylindrical pin tool. The carbonitriding pre-treatment of Al-2024 alloy demonstrated significant improvement in the tensile strength, percentage elongation, abrasion wear resistance and corrosion resistance with the sacrifice of impact strength. The maximum tensile strength of all three sets of samples after FSW was recorded in descending order of (i) carbonitrided-Al2024:carbonitrided-Al2024 (ii) Al2024:Carbonitrided-Al2024 and (iii) Al2024:Al2024. The friction stir welded joint of carbonitrided aluminium alloy exhibited best abrasive wear resistant and corrosion resistant properties.

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Lee, Ho Sung, Koo Kil No, Joon Tae Yoo, and Jong Hoon Yoon. "A Study on Friction Stir Welding Process for AA2219/AA2195 Joints." Key Engineering Materials 762 (February 2018): 339–42. http://dx.doi.org/10.4028/www.scientific.net/kem.762.339.

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The object of this study was to study mechanical properties of friction stir welded joints of AA2219 and AA2195. AA2219 has been used as an aerospace materials for many years primarily due to its high weldability and high specific strength in addition to the excellent cryogenic property so to be successfully used for manufacturing of cryogenic fuel tank for space launcher. Relatively new Aluminum-Lithium alloy, AA2195 provides significant saving on weight and manufacturing cost with application of friction stir welding. Friction stir welding is a solid-state joining process, which use a spinning tool to produce frictional heat in the work piece. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool, and the experiment was conducted under the condition that the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. Tensile tests were conducted to study the strength of friction stir welded joints and microhardness were measured with microstructural analysis. The results indicate the failure occurred in the relatively weaker TMAZ/HAZ interface of AA2219. The optimum process condition was obtained at the rotation speed of 600-800 rpm and the travelling speed of 180-240 mm/min.

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Ahmed, Mohamed M. Z., Mohamed M. El-Sayed Seleman, Dariusz Fydrych, and Gürel Çam. "Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review." Materials 16, no. 8 (April 8, 2023): 2971. http://dx.doi.org/10.3390/ma16082971.

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The use of the friction stir welding (FSW) process as a relatively new solid-state welding technology in the aerospace industry has pushed forward several developments in different related aspects of this strategic industry. In terms of the FSW process itself, due to the geometric limitations involved in the conventional FSW process, many variants have been required over time to suit the different types of geometries and structures, which has resulted in the development of numerous variants such as refill friction stir spot welding (RFSSW), stationary shoulder friction stir welding (SSFSW), and bobbin tool friction stir welding (BTFSW). In terms of FSW machines, significant development has occurred in the new design and adaptation of the existing machining equipment through the use of their structures or the new and specially designed FSW heads. In terms of the most used materials in the aerospace industry, there has been development of new high strength-to-weight ratios such as the 3rd generation aluminum–lithium alloys that have become successfully weldable by FSW with fewer welding defects and a significant improvement in the weld quality and geometric accuracy. The purpose of this article is to summarize the state of knowledge regarding the application of the FSW process to join materials used in the aerospace industry and to identify gaps in the state of the art. This work describes the fundamental techniques and tools necessary to make soundly welded joints. Typical applications of FSW processes are surveyed, including friction stir spot welding, RFSSW, SSFSW, BTFSW, and underwater FSW. Conclusions and suggestions for future development are proposed.

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van der Laan, A. H., R. Curran, M. J. L. van Tooren, and C. Ritchie. "Integration of friction stir welding into a multi-disciplinary aerospace design framework." Aeronautical Journal 110, no. 1113 (November 2006): 759–66. http://dx.doi.org/10.1017/s0001924000001627.

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Abstract Multidisciplinary design and innovative highly automated manufacturing methods are increasingly important to today’s aircraft industry: multidis-ciplinary design because it reduces lead-time and results in a better design, and automated manufacturing methods because they are more capable and reduce manufacturing cost. In this paper a cost estimation model is presented that integrates the manufacturing cost of friction stir welded connections within a multidisciplinary design decision tool. Due to the fact that friction stir welding is a new manufacturing method, the cost estimation model is based on the actual process physics, meaning what the process looks like in terms of processing speeds and characteristics. As an integral part of a multidisciplinary design framework, the developed cost estimation model contributes to a design support tool that assesses not only manufacturing but also structural and aerodynamic issues. It is shown that the cost model developed can be integrated into this more holistic design process support architecture. The predicted costs are accurate to the historical data and allow tradeoff of manufacturing and economic considerations within the context of the multidisciplinary design tool. The tradeoff capability is highlighted through a presented case study that compares the friction stir welding process as an alternative solution to more tradition riveting. Most importantly, this results in a quantitative tradeoff between two processes that shows the manufacturing cycle time of friction stir welding to be reduced by 60% and the recurring assembly cost by 20%.

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Journal articles on the topic 'Aerospace friction stir welded components'

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