Abstract
The restoration of numerous aircraft structures is achievable with effective repair of welded joints. T-joints are often utilized in these structures to provide structural stability, keeping minimal body weight. Multi-pass friction stir welding (FSW) has proved to be useful for improving the quality of aluminium alloy welds employed in the aerospace sector. However, FSW of these alloys in T-configuration has not been sufficiently addressed yet. Even rarer is the discussion of efficacy of second FSW pass, with altered process parameters for improving the weld quality in T-joints. Hence, two commonly used aerospace grade aluminium alloys, namely, AA2024 and AA7075, were friction stir welded in T-configuration, varying three process parameters, i.e., tool rotational speed, welding speed and shoulder diameter. The effect of second FSW pass, performed at an optimum set of parameters, on kissing bond and tunnelling defect was studied in detail. A substantial reduction in the detrimental effect of these weld defects was discussed via tensile testing, micro-hardness and micro-structural observations.
Highlights
The safety and structural integrity of aircraft structures are largely dependent upon the skin-stringer joining [1,2,3]
Studies conducted by Sathari et al [28] showed improved hardness, tensile strength and ductility for friction stir welds obtained via double pass, on comparison with the welds obtained through single pass
The effect of second friction stir pass performed with changed process parameters upon the weld defects, micro-structural and mechanical properties has been addressed in detail
Summary
The safety and structural integrity of aircraft structures are largely dependent upon the skin-stringer joining [1,2,3]. Zhao et al [22] demonstrated the disparity in the effects of kissing bond and tunnelling defect in deterioration of the weld strength along the skin and stringer, respectively. Studies conducted by Sathari et al [28] showed improved hardness, tensile strength and ductility for friction stir welds obtained via double pass, on comparison with the welds obtained through single pass. The potential for increase of friction stir weld properties by double pass has scarcely been utilized for dissimilar skin-stringer joining in general and 7xxx-2xxx combination in particular. The effect of second friction stir pass performed with changed process parameters upon the weld defects, micro-structural and mechanical properties has been addressed in detail
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