Friction Stir Welded Aluminum Machining Preforms [ FSWAMP ]

Applied Optimization, Inc., in working with EWI, Inc. and Boeing Phantom Works, proposes to demonstrate application of friction stir welding [FSW] for the manufacturing of a large aluminum 7050-T7451 component that is representative of a canted bulkhead. The FSW-based redesign is lighter, makes use of commercial off-the-shelf product forms, and is expected to reduce the lead time and the costs of raw materials and manufacturing. The strength debit due to FSW is compensated by local thickening of the cross-section. The placement of FSW seams is designed to permit non-destructive inspection. The FSW path is chosen so to as not require a specialized machine. The work plan has the following basic elements: [1] Develop process qualification record for the FSW, post weld heat treatment, and the non-destructive evaluation procedure. [2] Develop preform geometry, FSW joint configurations, and optimal sequence for preform assembly [3] Optimize the thermal pattern and minimize weld distortions [4] Develop modular tooling and fabricate the representative component [5] Perform mechanical tests and NDI, [6] Develop metric for cost and weight reduction due to FSW as compared to the original design.