Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

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 involv...

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Bibliographic Details
Published inMaterials Vol. 16; no. 8; p. 2971
Main Authors Ahmed, Mohamed M. Z., El-Sayed Seleman, Mohamed M., Fydrych, Dariusz, Çam, Gürel
Format Journal Article
LanguageEnglish
Published Switzerland MDPI AG 08.04.2023
MDPI
Subjects
Aerospace industry
Aerospace materials
Aircraft industry
Alloys
Aluminum alloys
Aluminum-lithium alloys
Composite materials
Cost control
Friction stir welding
Geometric accuracy
Industrial development
Machining
Magnesium alloys
Manufacturing
Pressure welding
Process controls
Review
Solids
Spot welding
State-of-the-art reviews
Steel alloys
Strength to weight ratio
Titanium alloys
Weld defects
Welded joints
Welding
Welding equipment
United States
United Kingdom
BTFSW
SSFSW
friction stir welding
aerospace industry
aluminum–lithium alloys
RFSSW
Online AccessGet full text
ISSN1996-1944
1996-1944
DOI10.3390/ma16082971

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Abstract 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.
AbstractList 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.
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.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.
Audience Academic
Author El-Sayed Seleman, Mohamed M.
Çam, Gürel
Ahmed, Mohamed M. Z.
Fydrych, Dariusz
AuthorAffiliation 4 Department of Mechanical Engineering, Iskenderun Technical University, Iskenderun 31200, Hatay, Türkiye
3 Institute of Machines and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
2 Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, Egypt
1 Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
AuthorAffiliation_xml – name: 3 Institute of Machines and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, Poland
– name: 4 Department of Mechanical Engineering, Iskenderun Technical University, Iskenderun 31200, Hatay, Türkiye
– name: 2 Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, Egypt
– name: 1 Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
Author_xml – sequence: 1
  givenname: Mohamed M. Z.
  orcidid: 0000-0002-9550-7431
  surname: Ahmed
  fullname: Ahmed, Mohamed M. Z.
– sequence: 2
  givenname: Mohamed M.
  orcidid: 0000-0002-6836-3874
  surname: El-Sayed Seleman
  fullname: El-Sayed Seleman, Mohamed M.
– sequence: 3
  givenname: Dariusz
  orcidid: 0000-0002-2557-8568
  surname: Fydrych
  fullname: Fydrych, Dariusz
– sequence: 4
  givenname: Gürel
  orcidid: 0000-0003-0222-9274
  surname: Çam
  fullname: Çam, Gürel
BackLink https://www.ncbi.nlm.nih.gov/pubmed/37109809$$D View this record in MEDLINE/PubMed
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aluminum–lithium alloys
RFSSW
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Snippet 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...
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SubjectTerms Aerospace industry
Aerospace materials
Aircraft industry
Alloys
Aluminum alloys
Aluminum-lithium alloys
Composite materials
Cost control
Friction stir welding
Geometric accuracy
Industrial development
Machining
Magnesium alloys
Manufacturing
Pressure welding
Process controls
Review
Solids
Spot welding
State-of-the-art reviews
Steel alloys
Strength to weight ratio
Titanium alloys
Weld defects
Welded joints
Welding
Welding equipment
Title Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review
URI https://www.ncbi.nlm.nih.gov/pubmed/37109809
https://www.proquest.com/docview/2806575499
https://www.proquest.com/docview/2807923495
https://pubmed.ncbi.nlm.nih.gov/PMC10143485
Volume 16
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