2 Fundamentals of Friction Stir Welding, Its Application, and Advancements
63
I, Orion Crew Vehicle (Fig. 2.13a), and shuttle64 by 2195 aluminum–lithium alloy
[95].
Germany based Airbus GmbH company and the Daimler/Chrysler aerospace
agency have shown interest in FSW. It is because of advantages i.e. weight reduction
of the structure, better joint strength, enhanced fatigue strength, and reduction in
cost. They used FSW for making the components of the airframe-structure ie. the
fuselage, passenger cabins, wings, and vertical stabilizers. The finishing assembly
of the narrow-fuselage aircraft mostly for the A3 series of Airbus A380 [97]. It
is to produce lengthwise joints in the fuselage, outer-link, and central container of
the wing with AA 2xxx and 7xxx aluminum alloy series. FSW is also used for
making panels for Airbus A400M, longitudinal and circumferential welds of Falcon
1 and Falcon 9 rocket fuel-promoter tank at the SpaceX factory [98]. Fokker space
company developed the main cryogenic stage engine body of the Arian-5 rocket, its
nose comprises of 12 integral flat panels of AA7075 with stiffeners. The aviation
company Eclipse Aviation was involved in the manufacturing of 5 seater airliner of
the private class Eclipse 500. It’s rigid stringer panels are made of AA2xxx (plating)
and 7xxx (stringers) groups of aluminum alloys [99].
ZE41A Mg alloy along with AA2024-T3 results in higher strength and is mainly
used for aircraft production and towards defense areas joining by dissimilar FSW
[100]. Also, ZE41A Mg is an anticorrosive alloy used for airplane gearbox and
generator casings in military choppers. As these are exposed to corrosive environments during service conditions [101]. The dissimilar joining of magnesium and
aluminum alloys are problematic because of significant differences in physical properties and development of intermetallic compounds i.e. Al 12 Mg 17 and Al 3 Mg 2 in
SZ [102]. Indian space research organization (ISRO) has made propellant tanks
constructed using FSW techniques [103].
2.7.3 Automobile
Companies are using FSW for the manufacturing of spatial frames of car structure,
components of the chassis, bodies of bus structure, fuel tanks, and other transportation
media [104]. Ford GT has efficiently welded aluminum extruded bend sheets and
fuel tank housing. In the automotive industries, it is used in the manufacturing of
hood panels, suspension links, and driveshafts [105]. FSW is extensively used in the
automotive industries and its outreach has reached beyond materials like aluminum
and magnesium. Few more application from automobile sector include rear seat
frame of 2001 Volvo V70), suspension components of 2003 Lincoln Town Car L,
hood and rear doors of 2004 Mazda RX-8, space frame parts of 2005 Ford GT and
2007 Audi R8, hood and trunk of 2006 Mazda MX-5 Miata, rear hatch parts of 2010
Toyota Plus and front subframe parts of 2013 Honda Accord (Fig. 2.14a) [102].
The most widely employed aluminum alloy in the automotive industry is AA7075
comprising of aluminum, zinc, magnesium, and copper. It is strongest of all aluminum
alloy group and is comparable to steel. It weighs about only one-third of the steel and
63
I, Orion Crew Vehicle (Fig. 2.13a), and shuttle64 by 2195 aluminum–lithium alloy
[95].
Germany based Airbus GmbH company and the Daimler/Chrysler aerospace
agency have shown interest in FSW. It is because of advantages i.e. weight reduction
of the structure, better joint strength, enhanced fatigue strength, and reduction in
cost. They used FSW for making the components of the airframe-structure ie. the
fuselage, passenger cabins, wings, and vertical stabilizers. The finishing assembly
of the narrow-fuselage aircraft mostly for the A3 series of Airbus A380 [97]. It
is to produce lengthwise joints in the fuselage, outer-link, and central container of
the wing with AA 2xxx and 7xxx aluminum alloy series. FSW is also used for
making panels for Airbus A400M, longitudinal and circumferential welds of Falcon
1 and Falcon 9 rocket fuel-promoter tank at the SpaceX factory [98]. Fokker space
company developed the main cryogenic stage engine body of the Arian-5 rocket, its
nose comprises of 12 integral flat panels of AA7075 with stiffeners. The aviation
company Eclipse Aviation was involved in the manufacturing of 5 seater airliner of
the private class Eclipse 500. It’s rigid stringer panels are made of AA2xxx (plating)
and 7xxx (stringers) groups of aluminum alloys [99].
ZE41A Mg alloy along with AA2024-T3 results in higher strength and is mainly
used for aircraft production and towards defense areas joining by dissimilar FSW
[100]. Also, ZE41A Mg is an anticorrosive alloy used for airplane gearbox and
generator casings in military choppers. As these are exposed to corrosive environments during service conditions [101]. The dissimilar joining of magnesium and
aluminum alloys are problematic because of significant differences in physical properties and development of intermetallic compounds i.e. Al 12 Mg 17 and Al 3 Mg 2 in
SZ [102]. Indian space research organization (ISRO) has made propellant tanks
constructed using FSW techniques [103].
2.7.3 Automobile
Companies are using FSW for the manufacturing of spatial frames of car structure,
components of the chassis, bodies of bus structure, fuel tanks, and other transportation
media [104]. Ford GT has efficiently welded aluminum extruded bend sheets and
fuel tank housing. In the automotive industries, it is used in the manufacturing of
hood panels, suspension links, and driveshafts [105]. FSW is extensively used in the
automotive industries and its outreach has reached beyond materials like aluminum
and magnesium. Few more application from automobile sector include rear seat
frame of 2001 Volvo V70), suspension components of 2003 Lincoln Town Car L,
hood and rear doors of 2004 Mazda RX-8, space frame parts of 2005 Ford GT and
2007 Audi R8, hood and trunk of 2006 Mazda MX-5 Miata, rear hatch parts of 2010
Toyota Plus and front subframe parts of 2013 Honda Accord (Fig. 2.14a) [102].
The most widely employed aluminum alloy in the automotive industry is AA7075
comprising of aluminum, zinc, magnesium, and copper. It is strongest of all aluminum
alloy group and is comparable to steel. It weighs about only one-third of the steel and