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Accession Number ADA574537
Title Friction Stir Welding of Thick Section Aluminum for Military Vehicle Applications.
Publication Date Dec 2012
Media Count 20p
Personal Author B. Thompson C. Niese K. Doherty M. Eff T. Stotler
Abstract This report will highlight the work conducted in developing production-level, single-pass friction stir welding (FSW) parameters for thicknesses ranging from 0.5 to 1.6 inches in aluminum alloys 5083, 5059, and 2139. This includes developing welding procedures to meet ballistic shock requirements, extending tool life greater than 500 in without loss in weld properties, and maximizing travel speeds. Phased array ultrasonic testing (PAUT) was selected as the primary inspection method due to its flexibility, portability, and accuracy in detecting common FSW defects. The high automation of the FSW process led to an inherently stable process, ensuring that the incidences of welding defects were limited. As such, the PAUT development effort focused on refining techniques for inspecting defects most likely to occur in a production environment over the range of expected FSW joints. This collaborative effort between the U.S. Army Research Laboratory, EWI, and General Dynamics Land Systems (GDLS) culminated in the construction and inspection of a military vehicle demonstrator hull at GDLS facilities in Lima, OH. The successful fabrication of this demonstration article represents a significant step forward in accepting FSW technology as a viable joining method for aluminum hulled military vehicles.
Keywords Aluminum alloys
Army research
Ballistic shock testing
Cross welds
Friction stir welding
Life expectancy(Service life)
Military vehicles
Paut(Phased array ultrasonic testing)
Phased arrays
Technology transfer
Tensile properties
Ultrasonic inspection

Source Agency Non Paid ADAS
NTIS Subject Category 41E - Manufacturing, Planning, Processing & Control
79D - Combat Vehicles
Corporate Author Army Research Lab., Aberdeen Proving Ground, MD. Weapons and Materials Research Directorate.
Document Type Technical report
Title Note Conference paper.
NTIS Issue Number 1318
Contract Number DAAD19-03-2-0002

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