Developing a Metal Joining Process for Fabricating Airframes

Abstract

Riveting and adhesive bonding have been the major processes for fabricating aluminium airframes for many decades. The development of Friction Stir Welding (FSW) now offers a serious challenge to these processes. Indeed there is little doubt that FSW is a serious contender to riveting. This is clearly demonstrated by the innovative design and development of the low cost Eclipse 500 personal jet aircraft. FSW has enabled substantial production cost, time and weight savings, without compromising mechanical integrity and quality. There is significant scope for developing and enhancing the use of FSW for fabricating joints involving thin sheet materials, especially for airframe fabrication. This presentation looks at the challenges and advantages to be gained. It embraces the good and the bad, covering: potential flaws that can occur in in-correctly made lap joints; preventing corrosion between lapped joints; the necessary objectives when developing future FSW tools for welding thin sheets; new airframe design opportunities involving thin sheets and; the potential opportunity for the development of small hand, or robot, positioned FSW machines that can be used for the attachment of fuselage skins in both production and repair.