Review of the Applicability of FSW Processing to Aircraft Applications

Kumar, B.; Widener, Christian; Jahn, Adam; Tweedy, Bryan; Cope, Dale A.; Lee, Ryan

doi:10.2514/6.2005-2000

Cited by 18 publications

(6 citation statements)

References 15 publications

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“…The second aluminum alloy, a hardenable, high-strength EN AW-2024-T3 [34], is frequently employed in aircraft manufacturing [35]. Due to its poor welding properties and low corrosion resistance, this alloy is usually adhesively bonded.…”

Section: Materials Combination Abbreviationmentioning

confidence: 99%

A Study on the Bond Strength of Plastic–Metal Direct Bonds Using Friction Press Joining

Meyer¹,

Herold²,

Habedank³

et al. 2021

Metals

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Friction press joining (FPJ) is an innovative joining process for bonding plastic components and metal sheets without additives in an overlap configuration. This paper focuses on the resulting bond strength. Tensile tests showed that the direct bonds produced by FPJ have either an equivalent or a higher bond strength compared to adhesive bonds. For the material combination of HD-PE and EN AW-6082-T6, an equivalent bond strength was achieved. In contrast, for the material combinations PA6-GF30 with EN AW-6082-T6 and PPS-CF with EN AW-2024-T3, higher tensile shear strengths were achieved via the FPJ technology. In addition to the technical considerations, this paper presents an evaluation of the technological maturity of FPJ. It was found that the basics of the technology are already well developed, and prototypes for showing the applicability have already been manufactured. The last part of this paper deals with the classification of FPJ into the standard for manufacturing processes, according to DIN 8593. The authors suggest a categorization into Activation bonding (item 4.8.1.3). These investigations show the high technical potential of FPJ for joining plastic components with metals.

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Section: Materials Combination Abbreviationmentioning

confidence: 99%

A Study on the Bond Strength of Plastic–Metal Direct Bonds Using Friction Press Joining

Meyer¹,

Herold²,

Habedank³

et al. 2021

Metals

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“…One technology with disruptive potential for fuselage shell assembly is friction stir welding (FSW), as it is capable of welding precipitated hardened alloys (eg, AA2024 aluminum alloy), creating high performing joints, with lower distortions than conventional fusion welding processes and easier weld quality control. By employing FSW in a butt joint configuration (see Figure A) in longitudinal joints, significant weight savings may be achieved through the removal of the overlap as well as fasteners.…”

Section: Introductionmentioning

confidence: 99%

Fatigue performance of hybrid overlap friction stir welding and adhesive bonding of an Al‐Mg‐Cu alloy

Braga

Maciel

Bergmann

et al. 2018

Fatigue Fract Eng Mat Struct

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The need for weight reduction and leaner manufacturing and assembly processes in aircraft construction has led to the pursuit of welding technologies. One such technology that has been considered for this application is friction stir welding (FSW). Since it is a solid‐state joining method, it creates high performing joints in a wide range of materials while avoiding overlap lengths and added weight from fasteners, crack stoppers, doublers, etc. However, the adoption of this technology to the assembly of large fuselage shell components is challenging, due to geometric tolerance management requirements. In this paper, a hybrid joining method is proposed for such application, involving FSW and adhesive bonding. Fatigue performance of single lap joints of AA2024‐T3 Al‐Mg‐Cu alloy was assessed and benchmarked against FSW overlap and adhesive bonded joints. Significant strength and ductility increase was achieved through the hybridization of the overlap FSW joints. Fatigue strength of the hybrid joints was also higher than FSW overlap joints, although not as high as adhesive bonded joints.

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“…Kumar et al [5] reviewed the applicability of FSW processing to aircraft applications and drew the conclusion that friction stir welding is gaining prominence as one of the principle joining techniques used in the aircraft industry. Kuwayama et al [6] studied fatigue crack propagation properties of a friction-stir-welded 2024-T3 aluminum alloy.…”

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confidence: 99%

Residual Stress Effects and Fatigue Behavior of Friction-Stir-Welded 2198-T8 Al-Li Alloy Joints

Irving

2011

Journal of Aircraft

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Applications of friction stir welding in a fuselage structure were studied. Samples with two different friction-stirweld orientations in the fuselage panel were tested: one is along the fuselage longitudinal direction and the other one is along the fuselage circumferential direction. Then fatigue cracks were investigated that were set in three different types: parallel and perpendicular to friction stir welds and between double welds. Sample geometries were machined from identical welds in order to remove the effect of the weld process on fatigue behavior. Tests were conducted on M (T) specimens with either longitudinal or transverse welds. Cracks growing into or growing away from the weld center, as well as in the nugget zone, were investigated. It is shown that fatigue crack growth for cracks growing away from the center seems similar to that of the parent material; for crack growing in the nugget, crack grows slower than in the parent material; and for cracks starting between double welds, the crack grows slower than in the other two types. The virtual crack-closure technique method was used to calculate stress intensity factor from residual stress (K res ) and effective R ratio in an attempt to explain the experimental findings.Nomenclature a = crack length da=dN = crack growth rate E = Young's modulus of elasticity F j = reaction force on the jth node G = strain-energy release rate K = stress intensity factor K res = stress intensity factor from residual stress N = cycle (fatigue load) R eff = R ratio with the presence of residual stress R nom = applied load R ratio t = thickness of samples u i = total displacement from the ith node c = element size

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Review of the Applicability of FSW Processing to Aircraft Applications

Cited by 18 publications

References 15 publications

A Study on the Bond Strength of Plastic–Metal Direct Bonds Using Friction Press Joining

A Study on the Bond Strength of Plastic–Metal Direct Bonds Using Friction Press Joining

Fatigue performance of hybrid overlap friction stir welding and adhesive bonding of an Al‐Mg‐Cu alloy

Residual Stress Effects and Fatigue Behavior of Friction-Stir-Welded 2198-T8 Al-Li Alloy Joints

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