Advanced Techniques For The Fabrication Of Airframe Structures Using Innovative Friction Stir Welding (FSW) Technology

One of the alternative method for welding method is a friction stir welding (FSW), which was developed in 1991 at TWI (The Welding Institute) in the United Kingdom, initially especially for joining aluminum and its alloys [1]. This process consists in joining of materials in solid state, which eliminates the problems resulting from melting the material and its re-solidifying, such as, hot cracking, residual stresses and distortion created during conventional welding. In this process, the heat which plasticized the material is provided by rotating tool consisting of shoulder and pin. This tool penetrates into the base material and then moves along the welding line. As a result of the friction between tool and joining materials is generated a sufficient amount of heat allowing on mixed the base material and create FSW joint. Among the most important advantages of using the FSW method should be listed: relatively easy automatization (it is often possible to use conventional CNC machine), lower residual stresses in the welded joints and their very good mechanical properties (often exceed the mechanical properties of welded or riveted joints). Project FAST_FSW (Advanced techniques for the Fabrication of Airframe STructures using innovative friction stir welding (FSW) technology) is realized within consortium between PZL Mielec and research partner Czestochowa University of Technology. The main objective of the FAST_FSW Project is to develop friction stir welding technology to aircraft design and manufacturing for introduce fasteners free, lighter weight and lower cost aerostructures.