TWI

A moving gantry five axis CNC friction stir welding (FSW) machine was developed to facilitate the production of complex curved fuselage components (e.g. stringer and frame) based on third generation 2A97 Al-Li alloys. A ribbed curved component incorporating curved skin, stringers and a frame was chosen to simulate the FSW process. Butt joints were fabricated in 2A97 alloy sheets (thickness 1.2 mm) using optimised FSW parameters and, on this basis, lap joints were produced at a rotational speed of 600-1200 rpm and a traverse speed of 100-400 mm/min. Mechanical properties were characterised by tensile strength and fatigue strength measurements. Single and complex curved simulated component welding tests are also discussed.

11th International Symposium, 17-19 May 2016, Session 7A: Applications II, Paper 01