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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MDPI AG
2023-04-01
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Online Access: | https://www.mdpi.com/1996-1944/16/8/2971 |
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author | Mohamed M. Z. Ahmed Mohamed M. El-Sayed Seleman Dariusz Fydrych Gürel Çam |
author_facet | Mohamed M. Z. Ahmed Mohamed M. El-Sayed Seleman Dariusz Fydrych Gürel Çam |
author_sort | Mohamed M. Z. Ahmed |
collection | DOAJ |
description | 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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id | doaj.art-08b15c5a3cbc413fbe8fd22f4fb54257 |
institution | Directory Open Access Journal |
issn | 1996-1944 |
language | English |
last_indexed | 2024-03-11T04:48:13Z |
publishDate | 2023-04-01 |
publisher | MDPI AG |
record_format | Article |
series | Materials |
spelling | doaj.art-08b15c5a3cbc413fbe8fd22f4fb542572023-11-17T20:11:14ZengMDPI AGMaterials1996-19442023-04-01168297110.3390/ma16082971Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art ReviewMohamed M. Z. Ahmed0Mohamed M. El-Sayed Seleman1Dariusz Fydrych2Gürel Çam3Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi ArabiaDepartment of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, EgyptInstitute of Machines and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdańsk, PolandDepartment of Mechanical Engineering, Iskenderun Technical University, Iskenderun 31200, Hatay, TürkiyeThe 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.https://www.mdpi.com/1996-1944/16/8/2971friction stir weldingaerospace industrySSFSWBTFSWRFSSWaluminum–lithium alloys |
spellingShingle | Mohamed M. Z. Ahmed Mohamed M. El-Sayed Seleman Dariusz Fydrych Gürel Çam Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review Materials friction stir welding aerospace industry SSFSW BTFSW RFSSW aluminum–lithium alloys |
title | Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review |
title_full | Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review |
title_fullStr | Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review |
title_full_unstemmed | Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review |
title_short | Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review |
title_sort | friction stir welding of aluminum in the aerospace industry the current progress and state of the art review |
topic | friction stir welding aerospace industry SSFSW BTFSW RFSSW aluminum–lithium alloys |
url | https://www.mdpi.com/1996-1944/16/8/2971 |
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