Abstract
Friction stir welding (FSW) has gained prominence as a transformative welding technique, especially for aerospace alloys, owing to its inherent advantages over conventional fusion welding methods. FSW offers distinct advantages, including minimized thermal distortion, improved mechanical properties, and a reduced heat-affected zone, addressing the challenges posed by traditional welding methods. Focused primarily on metals alloys and composites, this study explores the main process parameters, tool materials, and design considerations, critical for achieving superior weld quality and mechanical performance. This chapter investigates into the microstructural evolution during FSW, emphasizing the impact of welding parameters on grain refinement and defect mitigation. The study also discusses recent advancements in tool design and process optimization techniques to enhance the efficiency and reproducibility of FSW in aerospace manufacturing.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Thomas WD, Nicholas ED, Needham JC, Murch MG, Templesmith P, Dawes CJ. Friction stir butt welding, GB Patent 9125978.8, International patent PCT/GB92/02203. 1991.
Padhy GK, Wu CS, Gao S. Friction stir based welding and processing technologies—processes, parameters, microstructures and applications: a review. J Mater Sci Technol. 2018;34(1):1–38.
Milčić M, Burzić Z, Radisavljević I, Vuherer T, Milčić D, Grabulov V. Experimental investigation of fatigue properties of FSW in AA2024-T351. Procedia Struct Integr. 2018;13:1977–84.
Badkoobeh F, Mostaan H, Rafiei M, Bakhsheshi-Rad HR, Berto F. Friction stir welding/processing of Mg-based alloys: a critical review on advancements and challenges. Materials (Basel). 2021;14(21):6726.
Staines DG, Thomas WM, Kallee SW, Oakley PJ. Friction stir technology—recent developments in process variants and applications. In: COM. Oct 1–4 2006.
Dalder E, Pastrnak JW, Engel J, Forrest RS, Kokko E, McTernan K, et al. Bobbin-tool friction—stir welding of thick-walled aluminum alloy pressure vessels. Weld J. 2008;87:40–4.
Ahmed MMZ, El-Sayed Seleman MM, Fydrych D, Çam G. Friction stir welding of aluminum in the aerospace industry: the current progress and state-of-the-art review. Materials (Basel). 2023;16(8):2971.
Mabuwa S, Msomi V. Review on friction stir processed TIG and friction stir welded dissimilar alloy joints. Metals (Basel). 2020;10(1):142.
Mishra RS, Ma ZY. Friction stir welding and processing. Mater Sci Eng. 2005;50:1–78.
Thomas WM, Johnson KI, Wiesner CS. Friction stir welding—recent developments in tool and process technologies. Adv Eng Mater. 2003;5:485–90.
Mishra R, Sidhar H. Friction stir welding of 2XXX Aluminum alloys including Al Li alloys. Oxford, Reino Unido: Butterworth-Heinemann; 2016.
Wang G, Zhao Y, Hao Y. Friction stir welding of high-strength aerospace aluminum alloy and application in rocket tank manufacturing. J Mater Sci Technol. 2018;34(1):73–91.
Meng X, Huang Y, Cao J, Shen J, dos Santos JF. Recent progress on control strategies for inherent issues in friction stir welding. Prog Mater Sci. 2021;115:100706.
Pikula J, Kwieciński K, Grzegorz Porembski AP. FEM simulation of the FSW process of heat exchanger components | Institute of Welding Bulletin. Bull Inst Weld. 2016;3:23–9.
Okninski A. Solid rocket propulsion technology for de-orbiting spacecraft. Chinese J Aeronaut. 2022;35(3):128–54.
Aldanondo E, Arruti E, Garagorri J, Echeverria A. Dissimilar aluminum-steel FSW lap joints. In: Friction stir welding and processing VIII. Cham: Springer International Publishing; 2016. p. 137–43.
Gaurav S, Mishra RS, Zunaid M. A critical review on mechanical and microstructural properties of dissimilar aluminum (Al)-magnesium (Mg) alloys. J Adhes Sci Technol. 2023;37(7):1117–49.
Jacquin D, Guillemot G. A review of microstructural changes occurring during FSW in aluminium. J Mater Process Tech. 2021;288:116706.
Çam G, Mistikoglu S. Recent developments in friction stir welding of al-alloys. J Mater Eng Perform. 2014;23(6):1936–53.
Ding Z, Fan Q, Wang L. A review on friction stir processing of titanium alloy: characterization, method, microstructure, properties. Metall Mater Trans B Process Metall Mater Process Sci. 2019;50(5):2134–62.
Li H, Gao J, Li Q. Fatigue of friction stir welded aluminum alloy joints: a review. Appl Sci. 2018;8(12):2626.
Kashaev N, Ventzke V, Çam G. Prospects of laser beam welding and friction stir welding processes for aluminum airframe structural applications. J Manuf Process. 2018;36:571–600.
Singh K, Singh G, Singh H. Review on friction stir welding of magnesium alloys. J Magn Alloy. 2018;6(4):399–416.
Singh VP, Patel SK, Ranjan A, Kuriachen B. Recent research progress in solid state friction-stir welding of aluminium–magnesium alloys: a critical review. J Mater Res Technol. 2020;9(3):6217–56.
Strawn C, Strauss AM. Investigation of friction stir welding for lunar applications. Acta Astronaut. 2023;210:364–71.
Bhojak V, Jain JK, Saxena KK, Singh B, Mohammed KA. Friction stir process: a comprehensive review on material and methodology. Indian J Eng Mater Sci. 2023;30(1):45–64.
Mabuwa S, Msomi V, Muribwathoho O, Saasebeng Motshwanedi S. The microstructure and mechanical properties of the friction stir processed TIG-welded aerospace dissimilar aluminium alloys. Mater Today Proc. 2021;46:658–64.
Anandan B, Manikandan M. Effect of welding speeds on the metallurgical and mechanical property characterization of friction stir welding between dissimilar aerospace grade 7050 T7651-2014A T6 aluminium alloys. Mater Today Commun. 2023;35:106246.
Gao F, Guo Y, Yang S, Yu Y, Yu W. Fatigue properties of friction stir welded joint of titanium alloy. Mater Sci Eng A. 2020;793:139819.
Nakazawa T, Sato YS, Kokawa H, Ishida K, Omori T, Tanaka K, et al. Friction stir welding of steels using a tool made of iridium-containing nickel base superalloy. In: Friction stir welding and processing VIII. Cham: Springer International Publishing; 2015. p. 77–82.
Lambiase F, Grossi V, Paoletti A. Friction stir joining of CFRP laminates with amorphous polymers: influence of processing speeds. J Manuf Process. 2020;55:186–97.
Lohwasser D, Chen Z. Friction stir welding. 1st ed. Cambridge: Woodhead Publishing; 2009.
Trimble D, O’Donnell GE, Monaghan J. Characterisation of tool shape and rotational speed for increased speed during friction stir welding of AA2024-T3. J Manuf Process. 2015;17:141–50.
Edwards PD, Ramulu M. Material flow during friction stir welding of Ti-6Al-4V. J Mater Process Tech. 2015;218:107–15.
Gangwar K, Ramulu M. Friction stir welding of titanium alloys: a review. Mater Des. 2018;141:230–55.
Carrasco JC, Berdugo I, Ospina R, Unfried SJ. Design optimization and fabrication of a thread tapered pin tool for friction stir welding. Visión electrónica. 2014;7(2):135–44.
Chen W, Wang W, Liu Z, Zhai X, Bian G, Zhang T, et al. Improvement in tensile strength of Mg/Al alloy dissimilar friction stir welding joints by reducing intermetallic compounds. J Alloys Compd. 2021;861:157942.
Eivani AR, Mehdizade M, Chabok S, Zhou J. Applying multi-pass friction stir processing to refine the microstructure and enhance the strength, ductility and corrosion resistance of WE43 magnesium alloy. J Mater Res Technol. 2021;12:1946–57.
Beygi R, Mehrizi MZ, Verdera D, Loureiro A. Influence of tool geometry on material flow and mechanical properties of friction stir welded Al-Cu bimetals. J Mater Process Technol. 2018;255:739–48.
Ashok Raj J, Murthy HNS, Arulmani L, Santosh Kumar H. A review on friction stir welded aluminium copper specimens. Adv Mater Process Technol. 2022;8(2):1255–69.
Dabeer P, Shinde G. Perspective of friction stir welding tools. Mater Today Proc. 2018;5(5):13166–76.
Sahlot P, Jha K, Dey GK, Arora A. Quantitative wear analysis of H13 steel tool during friction stir welding of Cu-0.8%Cr-0.1%Zr alloy. Wear. 2017;378–379:82–9.
Fernandez GJ, Murr LE. Characterization of tool wear and weld optimization in the friction-stir welding of cast aluminum 359+20% SiC metal-matrix composite. Mater Charact. 2004;52(1):65–75.
Thomas WM, Braithwaite ABM, John R. SKEW-STIR™ TECHNOLOGY. In: 3rd International Symposium on Friction Stir Welding. Kobe (Japan); 2001.
Ferreira FB, Felice I, Brito I, Oliveira JP, Santos T. A review of orbital friction stir welding. Metals (Basel). 2023;13(6):1055.
Martin J, Wei S. Friction stir welding technology for marine applications. In: Friction stir welding and processing VIII. Cham: Springer International Publishing; 2016. p. 219–26.
Curtis T, Widener C, West M, Jasthi B, Hovanski Y, Carlson B, et al. Friction stir scribe welding of dissimilar aluminum to steel lap joints. In: Friction stir welding and processing VIII. Cham: Springer International Publishing; 2016. p. 163–9.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this chapter
Cite this chapter
Del Sol, I., Salguero, J., Batista, M., Astarita, A., Vázquez, J.M. (2024). Friction Stir Welding for Aerospace Alloys. In: Gürgen, S. (eds) Joining Operations for Aerospace Materials. Sustainable Aviation. Springer, Cham. https://doi.org/10.1007/978-3-031-59446-5_8
Download citation
DOI: https://doi.org/10.1007/978-3-031-59446-5_8
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-59445-8
Online ISBN: 978-3-031-59446-5
eBook Packages: EngineeringEngineering (R0)