scholarly journals Data-Driven Analysis of Friction Stir Welding for Aerospace Applications

2021 ◽  
Author(s):  
Marta Camps ◽  
Maddi Etxegarai ◽  
Francesc Bonada ◽  
William Lacheny ◽  
Dorick Ballat-Durand ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Industry 4.0 ◽  
Manufacturing Sector ◽  
Welding Process ◽  
Abnormal Behavior ◽  
Smart Manufacturing ◽  
Friction Stir ◽  
Aerospace Applications ◽  
Final Assembly ◽  
Aerospace Manufacturing

Industry 4.0 and the digitalization of the manufacturing processes have brought new opportunities and strategies for process control and optimization. Friction Stir Welding is becoming a relevant manufacturing technology for several applications, among them the aerospace sector. This work presents the first data analysis and characterization of the Friction Stir Welding process of the Pre-Final Assembly Line of the new Ariane 6 launcher. Process monitoring data is captured and analyzed to provide predictive quality solutions for improving manufacturing key performance indicators and bring smart manufacturing and Industry 4.0 digitalization into the aerospace manufacturing sector. The results show promising performance for abnormal behavior detection, leveraging on a tailored data manipulation approach for this unique use case.

scholarly journals Friction Stir Welding of Aerospace Alloys

2019 ◽  
Vol 48 (1) ◽  
pp. 37-46
Author(s):  
Akshansh Mishra ◽  
Devarrishi Dixit
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Space Vehicles ◽  
Friction Stir ◽  
Aerospace Applications ◽  
Aerospace Alloys ◽  
Fuel Tanks ◽  
Higher Temperature ◽  
Solid State Joining ◽  
Joining Process

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.

scholarly journals Mechanical performance research of friction stir welding robot for aerospace applications

2021 ◽  
Vol 18 (1) ◽  
pp. 172988142199654
Author(s):  
Haitao Luo ◽  
Fengqun Zhao ◽  
Siwei Guo ◽  
Changshuai Yu ◽  
Guangming Liu ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Working Conditions ◽  
Mechanical Performance ◽  
Welding Process ◽  
Normal Displacement ◽  
Welding Robot ◽  
Friction Stir ◽  
Aerospace Applications ◽  
System Composition ◽  
Strength And Stiffness

The friction stir welding robot for aerospace applications developed by the research group is subject to the effects of size, working conditions, and other conditions during the operation. The load conditions of the friction stir welding robot are harsh, and the strength and stiffness tests of the whole machine need to be carried out. Five typical working conditions of the friction stir welding robot are analyzed. By analyzing the system composition and configuration of the robot, the loading conditions of the robot stirring head during the welding process are accurately simulated, and this is used as the stiffness and strength check. The boundary conditions of the robot are simulated and analyzed under typical working conditions. The results show that the data of each part of the robot under load are obtained for a given size of the rocket cap welding. After analysis, the maximum normal displacement of the friction stir welding robot reached 0.6424 mm and the maximum stress was 79.21 MPa under the condition of melon flap welding.

Studies on Friction Stir Welding of Al-Cu-Li (AA2195) Alloy

2015 ◽  
Vol 830-831 ◽  
pp. 274-277
Author(s):  
M. Agilan ◽  
R. Anbukkarasi ◽  
T. Venkateswran ◽  
Paul G. Panicker ◽  
Sathish V. Kailas ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotation Speed ◽  
Welding Process ◽  
High Strength ◽  
Travel Speed ◽  
High Modulus ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Aerospace Applications ◽  
Tool Rotation

For aerospace applications, Al-Cu-Li alloys are more attractive than conventional aluminum alloys due to their low density, high modulus and high strength. AA2195 is a third generation Al-Li alloy, developed with improved weldability. In this study, AA2195 alloy of 5mm thick sheets were welded by friction stir welding process (FSW). Tool rotational speed was varied from 400 rpm to 1000 rpm at constant travel speed of 60mm/min. Optimum tool rotation speed was identified and defect free weld coupons were processed with optimized parameter. Mechanical properties and micro structural characterization have been conducted on FSW welds.

Study of the Key Issues of Friction Stir Welding of Titanium Alloy

2010 ◽  
Vol 638-642 ◽  
pp. 1185-1190 ◽  
Author(s):  
Hui Jie Liu ◽  
Li Zhou ◽  
Yong Xian Huang ◽  
Qi Wei Liu
Keyword(s):  
Titanium Alloy ◽  
Friction Stir Welding ◽  
Melting Point ◽  
Titanium Alloys ◽  
Welding Process ◽  
High Strength ◽  
Liquid Cooling ◽  
Friction Stir ◽  
Key Issues ◽  
Aluminum And Magnesium Alloys

As a new solid-state welding process, friction stir welding (FSW) has been successfully used for joining low melting point materials such as aluminum and magnesium alloys, but the FSW of high melting point materials such as steels and titanium alloys is still difficult to carry out because of their strict requirements for the FSW tool. Especially for the FSW of titanium alloys, some key technological issues need to solve further. In order to accomplish the FSW of titanium alloys, a specially designed tool system was made. The system was composed of W-Re pin tool, liquid cooling holder and shielding gas shroud. Prior to FSW, the Ti-6Al-4V alloy plates were thermo-hydrogen processed to reduce the deformation resistance and tool wear during the FSW. Based on this, the thermo-hydrogen processed Ti-6Al-4V alloy with different hydrogen content was friction stir welded, and the microstructural characterizations and mechanical properties of the joints were studied. Experimental results showed that the designed tool system can fulfill the requirements of the FSW of titanium alloys, and excellent weld formation and high-strength joint have been obtained from the titanium alloy plates.

Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools

2012 ◽  
Vol 622-623 ◽  
pp. 323-329
Author(s):  
Ebtisam F. Abdel-Gwad ◽  
A. Shahenda ◽  
S. Soher
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Tensile Behavior ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Friction Stir ◽  
Aluminum Base ◽  
Tool Pin ◽  
Strength And Ductility

Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.

Thermo-Mechanical Modelling of Friction Stir Welding Process

2013 ◽  
Vol 774-776 ◽  
pp. 1155-1159 ◽  
Author(s):  
Xiao Cong He
Keyword(s):  
Finite Element Analysis ◽  
Friction Stir Welding ◽  
Mechanical Behaviour ◽  
Material Flow ◽  
Welding Process ◽  
Element Analysis ◽  
Friction Stir ◽  
Mechanical Modelling ◽  
Major Factors ◽  
Realistic Prediction

Friction stir welding (FSW) is a solid-state welding process where no gross melting of the material being welded takes place. Numerical modelling of the FSW process can provide realistic prediction of the thermo-mechanical behaviour of the process. Latest literature relating to finite element analysis (FEA) of thermo-mechanical behaviour of FSW process is reviewed in this paper. The recent development in thermo-mechanical modelling of FSW process is described with particular reference to two major factors that influence the performance of FSW joints: material flow and temperature distribution. The main thermo-mechanical modelling used in FSW process are discussed and illustrated with brief case studies from the literature.

A Thermo-Fluid Analysis of the Friction Stir Welding Process

2007 ◽  
Vol 539-543 ◽  
pp. 3832-3837 ◽  
Author(s):  
D. Jacquin ◽  
Christophe Desrayaud ◽  
Frank Montheillet
Keyword(s):  
Friction Stir Welding ◽  
Bulk Material ◽  
Welding Process ◽  
Vertical Motion ◽  
Velocity Fields ◽  
Fluid Simulation ◽  
Metal Sheet ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Fluid Analysis

The thermo-mechanical simulation of Friction Stir Welding focuses the interest of the welding scientific and technical community. However, literature reporting material flow modeling is rather poor. The present work is based on the model developed by Heurtier [2004] and aims at improving this thermo-fluid simulation developed by means of fluid mechanics numerical and analytical velocity fields combined together. These various velocity fields are investigated separately and especially according to the power dissipated during the flow. Boundary conditions are considered through a new approach based on the kinematic analysis of the thread of the pin. An equilibrium is established between the vertical motion of the bulk material dragged in the depth of the metal sheet, and its partial circulation around the pin. The analyses of the obtained velocity fields enable the understanding of the welded zone asymmetry and highlights the bulk material mixing between the welded coupons in the depth of the sheet. A regression is performed on the relative sliding velocity of the aluminium according to the surface of the tool: shoulder and pin. Two dimension flow lines in the depth of the metal sheet are then obtained and successfully compared with the results obtained by Colegrove (2004) [1].

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