Fusion welding

Butt welding

Engineering

Aerospace engineering

Butt joint

Metallurgy

Materials science

Friction stir welding

Joint (building)

Aluminium alloy

Aerospace

Alloy

Microstructure

Lap joint

Composite material

Spot welding

Structural engineering

Welding

Aluminium

Rivet

Materials Testing

This paper aims to validate the viability of friction stir welding process (FSW) to join high strength aerospace grade AA2014-T6 aluminium alloy for manufacturing light-weight combat aircraft (LCA) structure as a replacement to riveting process. FSW is used to overcome the heat input-related problems in fusion welding of AA2014-T6 aluminium alloy such as coarse grain fusion zone microstructure, softening in HAZ and lower joint efficiency. The 2 mm thick AA2014-T6 aluminium alloy sheets were used as the base material (BM). Friction stir butt (FBW) and friction stir lap (FLP) joints were developed, and its performance was compared with double cover riveted butt (DRB) joint in butt (RBJ) and lap (RLJ) joint configuration. Results showed that the load-carrying capability of FSW joints is greater than the riveted joints. The superior load-carrying capacities of FBW and FLW joints refers to evolution of refined grains and strengthening precipitates in stirred zone (SZ), which ensures superior metallurgical bonding between the joining surfaces. The riveted joints disclosed inferior load-carrying capacities due to the lack of metallurgical connection between the joining surfaces.

Friction stir welding for manufacturing of a light weight combat aircraft structure