C. B. Smith, Friction Stir Link, Waukesha, WI; R. Anderson, Keystone Synergistic, Palm Beach Gardens, FL
A novel friction stir welding (FSW) technique has been developed that is a combined welding and forging process. This technique is an additive manufacturing process that can be used for manufacture of fabricated shapes or structural assemblies, and can dramatically reduce buy-to-fly ratios. The welding process is used to join flat (or curved) shapes into tee or I-beam configurations and the forging process is used to form an integral fillet at the intersection of these individual components. A development and testing program was undertaken to develop a viable welding / forging process. The results of this development and testing program will be discussed. Using the process various prototype shapes and assemblies have been fabricated. These and other potential applications will be discussed.
Summary: A friction stir welding method has been developed that allows for efficient fabrication of tee shapes, I-beam shapes, and complex assemblies to significantly improve buy-to-fly ratios. The method is an additive manufacturing process that combines friction stir welding and forging processes. The method allows for 100% joint coverage and generation of a fillet on the backside to improve fatigue performance.
