Automatic Tracking of Blind Sealant Paths in Friction Stir Lap Joining

Gibson, Brian T.; Cox, Chase; Ballun, M.C.; Cook, Gerald; Strauss, Alvin M.

doi:10.2514/1.c032470

Cited by 7 publications

(4 citation statements)

References 18 publications

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“…The need to combine surface treatments, sealants and joining technologies is a continuous challenge in the manufacturing of structures such as reinforced fuselage panels. In fact, several authors investigated the feasibility of FSW and its derivatives such as refill friction stir spot welding (RFSSW) for joining surface-treated aluminium alloys in the overlap configuration using sealants [13][14][15][16][17]. These studies showed a promising potential of FSW technologies to join surface-treated aluminium alloys using sealants in appropriate welding conditions.…”

Section: Introductionmentioning

confidence: 99%

Fretting Fatigue as a Limiting Factor on the Durability of Friction Stir Welded Lap Joints Using AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Aldanondo

Zubiri

Vivas

et al. 2022

JMMP

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Friction stir welding (FSW) has been proposed as an alternative modern joining technology and demonstrated important benefits for the manufacturing of efficient and lightweight aircraft structures using high-strength aluminium alloys. These structures are required to be corrosion- resistant and thus, it is necessary to use technologies such as surface treatments and sealants in their manufacturing and assembly. In this work, the feasibility of combining innovative Cr-free surface treatments, sealants and FSW technology was investigated with the focus on the durability of the joints in fatigue. FSW lap joints were produced using AA2099-T83 extrusions and AA2060-T8E30 sheets in the as-received or surface-treated condition. A sealant was also applied in some cases at the overlapping interface before the FSW process. Static tensile tests and fatigue tests were carried out applying hoop-stress loading conditions. Different fracture modes were identified depending on the stress levels applied in the fatigue tests: High stress levels resulted in fractures in the HAZ of the FSW joints, while the specimens tested at low stress levels showed fractures out of the FSW joint. In general, FSW joints produced using surface-treated aluminium components and sealant presented improved fatigue life and extended durability in comparison with non-treated aluminium joints. The surface treatments and sealant at the interface of AA2099-T83 extrusions and AA2060-T8E30 sheets reduced the friction and local damage produced due to the sliding movement during the fatigue tests, minimizing the fretting fatigue effect, which was found to be the main limiting factor on the durability and fatigue life of the FSW joints.

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Section: Introductionmentioning

confidence: 99%

Fretting Fatigue as a Limiting Factor on the Durability of Friction Stir Welded Lap Joints Using AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Aldanondo

Zubiri

Vivas

et al. 2022

JMMP

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show abstract

“…From a general manufacturing of aircraft structures point of view, it is necessary to investigate the feasibility to combine surface treatments, sealants, and joining technologies. Several authors investigated the feasibility of FSW and its derivatives such as refill friction stir welding (RFSSW) for joining surface-treated aluminium alloys in the overlap configuration using sealants [28][29][30][31][32]. These studies demonstrated a good potential of FSW technologies to weld surface-treated aluminium alloys using sealants with appropriate welding conditions and materials.…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Welding of AA2099-T83 and AA2060-T8E30 Aluminium Alloys with New Cr-Free Surface Treatments and Sealant Application

Aldanondo

Vivas

Álvarez

et al. 2021

Metals

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The feasibility for friction stir welding (FSW) surface-treated AA2099-T83 aluminium extrusions with AA2060-T8E30 aluminium sheets in the overlap configuration and using a sealant at the interface was investigated in this work. New Cr-free surface treatments such as thin film sulphuric acid anodising (TFSAA) and sol–gel were applied to the parent materials, and a sealant was applied before applying the FSW process. FSW welds were produced using several combinations of surface treatments and sealant application with no significant influence on FSW process stability and performance. The metallographic examination of the welds showed that a good protection of the crevice was achieved with some sealant accumulation at the edges of the overlapping region. The microstructural analysis showed no sealant remnants but the presence of some oxide remnants in the stir zone (SZ) of the welds, especially in the TFSAA treated parent material cases. However, these remnants did not show any significant effect in the static pull-out strength of the joints and failures at the most stressed zone of the AA2099-T83 extrusions outside the FSW weld region were consistently obtained.

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“…Accordingly, several researchers have made efforts around the detection technologies to detect this special joint. A control system for automatic seam tracking for T-joint FSW based on weaving was presented [17,18], in the proposed technology, the tool weaves back and forth perpendicular to the joint line during welding in order to discover the position of maximal axial force, which is shown to be the center of the weld. The information of deviation status is acquired by the metallic vapor plume, which is influenced by instability or rupture of keyhole while the torch deviates from the weld seam [19].…”

Section: Introductionmentioning

confidence: 99%

Research on the Weld Position Detection for the T-Joints in Web-Core Sandwich Panels Based on Eddy Current Technology

Wei

Chang

Meng

et al. 2020

Sensors

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Web-core sandwich panels have gained the popularity in various fields, especially aviation and shipbuilding, etc. Penetration welding was considered as an effective process to manufacture such a structure through a T-joint. To ensure the formation quality and mechanical properties of weld, the welding torch needs to be aligned with the T-joint position. However, it is difficult to locate the T-joint position (i.e., the position of core panel) because of the shielding of the face panels. This paper investigated the detection of T-joint position from the face panel side in web-core sandwich panels based on eddy current technology. First, we designed an experimental system for the weld position detection of T-joints from the face panel side. The relationships are investigated between the characteristics of the eddy current detection signal and the primary parameters of the detection system (including excitation frequency, coil outer diameter, and lift off distance) and the T-joint (including thickness of the core panel, gap distance, and thickness of the cover panel). Corresponding experiments were carried out with variable primary parameters, and the influence mechanism of the primary parameters on the detection results in terms of sensitivity and dynamic performance was elaborated to set up the theoretical basis for the detection. Finally, weld position detection experiments were carried out on TC4 titanium alloy T-joint specimens with 3 mm-thick face panel and 5 mm-thick core panel. Results showed that the maximum detection error was 0.482 mm, and the average error was 0.234 mm. This paper provided a possible technical solution to the automatic tracking problem for the welding of T-joints in the web-core sandwich panels.

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Automatic Tracking of Blind Sealant Paths in Friction Stir Lap Joining

Cited by 7 publications

References 18 publications

Fretting Fatigue as a Limiting Factor on the Durability of Friction Stir Welded Lap Joints Using AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Fretting Fatigue as a Limiting Factor on the Durability of Friction Stir Welded Lap Joints Using AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Friction Stir Welding of AA2099-T83 and AA2060-T8E30 Aluminium Alloys with New Cr-Free Surface Treatments and Sealant Application

Research on the Weld Position Detection for the T-Joints in Web-Core Sandwich Panels Based on Eddy Current Technology

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