Macrostructure Integration of Airframe Structures via Friction Stir Welding

Friction Stir Welding (FSW) has been used to join smaller, inexpensive aluminuim sheets to eliminate fasteners in aircraft structures. This program will continue the Phase 1 research on quantifying the design benefits of FSW aluminum sheets of differing thickness of the same or different materials to tailor the structureal properties for airframe applications. By taioring the material and/or thickness to allow higher strength capability near stess concentrations, fillet radii, doors or other features, weight can be reduced by using lower strength material and or thinner product than is conventionally used, i.e. higher cost materials are used only where necessary. Additionally, T-joint FSW with fillet radii will further enhance structural design flexability to offer the potential for lighter weight structures. Under this program an analysis of potential design improvements with regard to weight and cost reductions will be completed as well as maturing T-joint FSW with fillet radii to make prototype components with these types of solid-state welds.