The increasing industrial demand to reduce structural weight, optimize structural strength, and high performance has led to the increasing use of tailors welded blanks. However, the joining of tailors welded blanks is an issue of concern to researchers owing to the difference in thickness between the materials in addition to the difference in physical and chemical properties in the case of dissimilar materials. These challenges in joining of tailors welded blanks are conquered by a recent solid phase joining process known as friction stir welding. This review work covers different methods of joining unequal thickness similar/dissimilar (or tailors welded blanks) aircraft materials in different joint configurations along with the challenges and failure modes encountered in these joining processes. From this article researchers and industrialists can take advantage and conquer relative limitations in order to meet the future challenges for joining of similar/dissimilar aircraft materials with unequal thickness
EzugwuEO.Key improvements in the machining of difficult to cut aerospace super-alloys. Int J Mach Manuf2005;
45: 1353–1367.
2.
MillerS.Advanced materials mean advanced engines. Interdiscip Sci Rev1995;
20: 117–129.
3.
AliBASapuanSMJawaidM, et al. Expert material selection for manufacturing of green bio-composites. Green Biocomposites.
Cham:
Springer International Publishing, 2017, pp.1–12.
4.
DeeviSCSikkaVK.Nickel and iron aluminides: an overview on properties, processing, and applications. Intermetallic1996;
4: 357–375.
5.
RoylanceD.Introduction to composite materials.
Cambridge, MA:
Massachusetts Institute of Technology, 2000, pp.21–39.
6.
SoutisC.Carbon fiber reinforced plastics in aircraft construction. Mater Sci Eng A2005;
412: 171–176.
7.
KolesnichenkoKY.Civil-military relations in the Soviet Far East during World War II (1939–1945): by the example of Primorsky Krai. J Slav Mil Stud2016;
29: 407–422.
8.
Adrian PM (ed.). Materials, and material requirements for aerospace structures and engines, Chapter 3. In: Introduction to aerospace materials. Cambridge: Woodhead Publishing Limited, 2012, pp.39–65.
9.
SahuPKPalS. Fatigue life behavior of single and double pass friction stir welded different thickness AA1050 joint. In: AIMTDR conference on manufacturing technology, design, and research, Pune, India, 16–18 December 2016, pp.1141–1145. ISBN: 978-93-86256-27-0
10.
BuffaGFratiniLHuaJ, et al.
Frictions stir welding of tailored blanks: an investigation on process feasibility. Ann CIRP2006;
55: 1–4.
11.
PohlT.Fertigungsqualitat and umformbarkeit laser strahlgeschweisster form platinenaus aluminium legierungen. PhD Thesis, Friedrich-Alexander-Universitat Erlangen-Nurnberg, Germany, 2002.
12.
DinkelF.Umformbarkeit von aluminium-karosserie-blechenmitneuartigenoberflachen. PhD Thesis, Technische Universitat Munchen, Germany, 1997.
13.
FratiniLBuffaGShivpuriR.Improving friction stir welding of blanks of different thicknesses. Mater Sci Eng A2007;
459: 209–215.
14.
BirolYKasmanS.Effect of welding parameters on microstructure and mechanical properties of friction stir welded ENAW5083 H111 plates. Mater Sci Technol2013;
29: 1354–1362.
15.
BozkurtYSalmanSCamG.Effect of welding parameters on lap shear tensile properties of dissimilar friction stir spot welded AA5754-H22/2024-T3 joints. Sci Technol Weld Join2013;
18: 337–345.
16.
MaggiolinoSSchmidC.Corrosion resistance in FSW and in MIG welding techniques of AA6XXX. J Mater Process Technol2008;
197: 237–240.
17.
PiotrMAmberGLorenzR.Mushy zone morphology calculation with the application of CALPHAD technique. Metals2017;
7: 363–381.
18.
GeigerMMerkleinMKerauschM.Finite element simulation of deep drawing of tailored heat treated blanks. Ann CIRP2004;
53: 223–226.
19.
RodriguesDMMenezesLFLoureiroA.The influence of the HAZ softening on the mechanical behavior of welded joints containing cracks in the weld metal.Eng Fract Mech2004;
71: 2053–2064.
20.
ZhangHTodaHQuPC, et al.
Three-dimensional fatigue crack growth behavior in an aluminum alloy investigated with in situ high-resolution synchrotron X-ray micro-tomography. Acta Mater2009;
57: 3287–3300.
21.
BocchiSCabriniMD’UrsoG, et al.
The influence of process parameters on mechanical properties and corrosion behavior of friction stir welded aluminum joints. J Manuf Process2018;
35: 1–15.
22.
MishraRSMaZY. Friction stir welding and processing. Mater Sci Eng R2005;
50: 1–78.
23.
VilacaPSantosJPGoisA, et al. Joining aluminum alloys dissimilar in thickness by friction stir welding and fusion processes. Weld World2005; 49: 56–62.
24.
BuffaGFratiniLShivpuriR.Finite element studies on friction stir welding processes of tailored blanks. Comput Struct2008;
86: 181–189.
25.
ZadpoorAASinkeJBenedictusR, et al.
Mechanical properties and microstructure of friction stir welded tailor-made blanks. Mater Sci Eng A2008;
494(1–2); 281–290.
26.
ChenCFanCCaiX, et al.
Analysis of droplet transfer, weld formation, and microstructure in Al-Cu alloy bead welding joint with the pulsed ultrasonic-GMAW method. J Mater Process Technol2019;
271: 144–151.
27.
GuptaMSVeeranjaneyuluK.Fabrication and analysis of adhesive joints used in aircraft structures. Mater Today Proc2017;
8: 8279–8286.
28.
Jiao JYeYJiaS, et al.
Experimental research on CFRTP-Al alloy laser butt joining. Procedia CIRP2020;
94: 521–525.
29.
KostrivasALippoldJC.Weldability of Li-bearing aluminium alloys. Int Mater Rev1990;
44: 217–237.
30.
BedairOKEastaughGF.A numerical model for the analysis of riveted splice joints accounting for secondary bending and plates/rivet interaction. Thin-Walled Struct2007;
45: 251–258.
31.
Zhang KChengHLiY.Riveting process modeling and simulating for deformation analysis of aircraft's thin-walled sheet-metal parts. Chin J Aeronaut2011;
3: 369–377.
32.
DoubravaR.Effect of mechanical properties of fasteners on stress state and fatigue behaviour of aircraft structures as determined by damage tolerance analyses. Proc Eng2015;
101: 135–142.
33.
KashaevNVentzkeVCamG.Prospects of laser beam welding and friction stir welding processes for aluminum airframe structural applications. J Manuf Process2018;
36: 571–600.
34.
ParkesPNButlerRMeyerJ, et al.
Static strength of metal composite joints with penetrative reinforcement. Compos Struct2014;
118: 250–256.
35.
HoffmannPGeigerM.Recent developments in laser system technology for welding applications. Ann CIRP1995;
44: 151–154.
36.
RicciardiGCantelloMMariottiF.On-line process control used in the laser welding of metal sheet lightweight structural panels. Ann CIRP1999;
48: 159–162.
37.
WangXLiWMa T, et al.
Microstructural heredity and its effect on mechanical properties of linear friction welded Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy joints. Mater Charact2020;
168: 1–32.
38.
SuJQNelsonTWMishraR, et al.
Microstructural investigation of friction stir welded 7050-T651aluminium. Acta Mater2003;
51: 713–729.
39.
HuangWWangTGarbatovY, et al.
Fatigue reliability assessment of riveted lap joint of aircraft structures. Int J Fatigue2012;
43: 54–61.
40.
ParkCYGrandtAF.Effect of load transfer on the cracking behavior at a countersunk fastener hole. Int J Fatigue2007;
29: 146–157.
41.
Messler Jr andRobert W.Joining of advanced materials. 1st ed.Waltham, MA:
Butterworth-Heinemann, 1993, p.560.
42.
CamGVentzkeVSantosJF, et al.
Characterization of laser and electron beam welded Al alloys. Pract Metall1999;
36: 59–89.
43.
MuchaJ.The effect of material properties and joining process parameters on the behavior of self-pierce riveting joints made with the solid rivet. Mater Des2013;
52: 932–946.
44.
GomezSOnoroJPecharrománJ.A simple mechanical model of a structural hybrid adhesive/riveted single lap joint. Int J Adhes Adhes2007;
27: 263–267.
45.
ChowdhuryNChiuWKWangJ, et al.
Static and fatigue testing thin riveted, bonded and hybrid carbon fiber double lap joints used in aircraft structures. Compos Struct2015;
121: 315–323.
46.
Hart-SmithJ.Bolted and bonded joints.ASM Handb1998;
21: 167–176.
47.
Bedair O.Stress field characteristics of eccentrically loaded aircraft spliced joints. Appl Math Modell2012;
36: 4543–4556.
48.
BabuTN.Structural analysis on wing box spliced joint for an aircraft using the finite element method. Int J Civil Eng Technol2017;
8: 2302–2313.
49.
CiesielskiMKaniowskiJ.Determination of fatigue crack growth rate from fractographic analysis of a specimen representing aircraft. Int J Fatigue2009;
31: 1102–1109.
50.
LeeHS.Diffusion bonding of metal alloys in aerospace and other applications.
Cambridge:
Woodhead Publishing Limited, 2012.
51.
LeeHSYoonJHYiYM.Manufacturing of titanium spherical and hollow cylinder vessel using blow forming. Key Eng Mater2009;
433: 57–62.
52.
HanWZhangKWangG, et al.
Superplastic forming and diffusion bonding for the sandwich structure of Ti6Al4V alloy. J Mater Sci Technol2005;
21: 60–62.
53.
Gietzelt T, Toth V and Huell A. Diffusion bonding: influence of process parameters and material microstructure. In: Joining Technologies 2016, pp. 195–216. London, UK: Intech Open.
54.
ÇamGIpekogluG.Recent developments in joining of aluminium alloys. Int J Adv Manuf Technol2017;
91: 1851–1866.
55.
ÇamGKocaM.Progress in joining of advanced materials. Int Mater Rev1998;
43: 1–44.
56.
HanBTaoWChenY, et al.
Double-sided laser beam welded T-joints for aluminum-lithium alloy aircraft fuselage panels: effects of filler elements on microstructure and mechanical properties. Opt Laser Technol2017;
93: 99–108.
57.
QiYChenG.Root defects in full penetration laser welding of thick plates using steady electromagnetic force. J Mater Process Technol2018;
260: 97–103.
58.
ViscusiALeitaoCRodriguesDM, et al.
Laser beam welded joints of dissimilar heat treatable aluminium alloys. J Mater Process Technol2016;
236: 48–55.
59.
ShaoWJHuangYZhangY.A novel weld seam detection method for space weld seam of narrow butt joint in laser welding. Opt Laser Technol2018;
99: 39–51.
RajendranCSrinivasanKBalasubramanianV, et al.
Effect of tool tilt angle on strength and microstructural characteristics of friction stir welded lap joints of AA2014-T6 aluminum alloy. Trans Nonferrous Met Soc China2019;
9: 1824–1835.
62.
HuangYMengXXieY, et al.
Friction stir welding/processing of polymers and polymer matrix composites. Compos Part A2018;
105: 235–257.
63.
CampbellFC.Joining: understanding the basics. Cleveland, OH: ASM International, 2011, 336 p.
64.
KimKYSimJJannatN, et al.
Challenges in riveting quality prediction: a literature survey. Proc Manuf2019;
38: 1143–1150.
65.
TarpaniACBarretoTATarpaniJ, et al.
Fatigue failure analysis of riveted fiber-metal laminate lap joints.Eng Fract Mech2020;
239: 1–13.
66.
CunxianWTaoSHaomaiaG, et al.
Determination of constitutive parameters for predicting dynamic behavior and failure of riveted joint: testing, modeling, and validation. Int J Impact Eng 2019; 132: 1–15.
67.
FrancoDFratiniGLPastaA.Influence of the distance between rivets in self-piercing riveting bonded joints made of carbon fiber panels and AA2024 blanks. Mater Des2012;
35: 342–349.
68.
MarannanoGZuccarelloB.Numerical experimental analysis of hybrid double lap aluminum CFRP joints. Compos Part B2015;
71: 28–39.
69.
PramanikABasakAKDongY, et al. Joining of carbon fiber reinforced polymer (CFRP) composites and aluminum alloys – a review. Compos. Part A Appl Sci Manuf 2017; 101: 1–29.
70.
GouldstoneC.Adhesive joining of curved metal and composite structures.
Cambridge:
Massachusetts Institute of Technology, 2002.
KrishnarajVZCollombetF.Comprehensive review on drilling of multi-material stacks. J Mach Form Technol2010;
2: 1–32.
73.
PittaSCarlesbVRourecF, et al.
On the static strength of aluminium and carbon fiber aircraft lap joint repairs. Compos Struct2018;
201: 276–290.
74.
ChenYYangXLi M, et al.
Mechanical behavior and progressive failure analysis of riveted, bonded, and hybrid joints with CFRP-aluminum dissimilar materials.Thin Walled Struct2019;
139: 271–280.
75.
SchillingCSantos JF. Method and device for linking at least two adjoining work pieces by friction welding. Patent 6722556B2, USA, 2004.
76.
MitschangPBlinzlerMWögingerA. Processing technologies for continuous fibre reinforced thermoplastics with novel polymer blends. Compos Sci Technol2003;
63: 2099–2110.
77.
AbibeABSônegoMdos SantosJF, et al.
On the feasibility of a friction based staking joining method for polymer metal hybrid structures. Mater Des2016;
92: 632–642.
78.
HuangYMengXXieY, et al.
New technique of friction-based filling stacking joining for metal and polymer. Compos Part BEng 2019; 163: 217–223.
79.
Amancio-Filho ST, Oliveira P, Bueno C, et al. Recent Advances In Joining Of Polymer And Polymer-Metal Hybrid Structures By Friction-Based Spot Welding Techniques. In: Proceedings for ANTECOrlando, USA, 18th May 2010.
80.
Amancio-FilhoaSTBuenoaCSantosaJF, et al.
On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures. Mater Sci Eng A2011;
528: 3841–3848.
81.
Konchakova N, Balle F, Barth FJ, et al. Finite element analysis of an inelastic interface in ultrasonic welded metal/fibre-reinforced polymer joints. Comp Mat sci 2010; 54: 184–190.
82.
BalleFWagnerGEiflerD.Ultrasonic metal welding of aluminium sheets to carbon fiber reinforced thermoplastic composites. Adv Eng Mater2009;
11: 35–39.
83.
BarneyJB.Gaining and sustaining competitive advantage.
Boston, MA:
Pearson,
2011.
84.
SakundariniNTahaZAbdul-RashidSH, et al.
Optimal multimaterial selection for lightweight design of automotive body assembly incorporating recyclability. Mater Des2013;
50: 846–857.
85.
SinkeJIaconoCZadpoorA.Tailor made blanks for the aerospace industry. Int J Mater Form2010;
3: 849–852.
86.
SaleemW. Application of topology optimization and manufacturing simulations – a new trend in the design of aircraft components. In: Proceedings of the international multi conference of engineers and computer scientists, Hong Kong, 19–21 March 2008, ISBN: 978-988-17012-1-3.
87.
PalletRJLarkRJ.The use of tailored blanks in the manufacture of construction components. J Mater Process Technol2001;
117: 249–254.
88.
ZadpoorAASinkeJBenedictusR. Bendability of machined aluminium tailor made blanks. J Mater Proc Technol2008; 200: 288–299.
SuJQNelsonTWMishraR, et al. Microstructural investigation of friction stir welded 7050-T651 aluminium. Acta Mater2003;
51: 713–729.
91.
SinkeJStofregenMMEstraatsmaE.Tailor made blanks for the aircraft industry: a pilot study. Technical report, Netherlands Institute for Metals Research, The Netherlands, 2005.
92.
ThreadgillPLLeonardAJShercliffHR, et al.
Friction stir welding of aluminium alloys. Int Mater Rev2009;
54: 49–93.
93.
Lienert TJ. Microstructure and mechanical properties of friction stir welded titanium alloys. In: Frict Stir Weld Process (ed. RS Mishra, MW Mahoney), 2007, pp. 123–154. ASME International.
94.
SiddiqueeANPandeyS.Experimental investigation on deformation and wear of WC tool during friction stir welding (FSW) of stainless steel. Int J Adv Manuf Technol2014;
73: 479−486.
95.
GrooverMP.Fundamentals of modern manufacturing: materials, processes, and systems.
Hoboken, NJ:
John Wiley & Sons, 2010.
96.
VilacaPFragaESaJ, et al. State of the art in the modelling of friction stir welding. FSW flow visualization and modelling seminar at GKSS Forschungszentrum, Germany, 24–25 February 2003.
97.
Khan NZ, Khan ZA, Siddiquee AN, et al. Analysis of defects in clean fabrication process of friction stir welding. Trans. of Nonferrous Met. Soc. China 2017; 27: 1507–1516.
98.
FieldDPNelsonTWHovanskiY, et al. Heterogeneity of crystallographic texture in friction stir welds of aluminum. Metall Mater Trans A2001;
32: 2869–2877.
99.
StrombeckASheikhiSSantosJF. Validation of Friction Stir Welding Process Models. In: Proc. 4th int. symp. on friction stir welding, Salt Lake City, UT, 14–16 May 2003, Cambridge: The Welding Institute/TWI.
100.
SheikhiSSantosJFD.Effect of process parameter on mechanical properties of friction stir welded tailored blanks from aluminium alloy 6181-T4. Sci Technol Weld Join2207;
12: 370–375.
101.
TavaresSMOSantosJFCastroPM.Friction stir welded joints of Al–Li alloys for aeronautical applications: butt-joints and tailor welded blanks. Theor Appl Fract Mech2013;
65: 8–13.
102.
SahuPKPalS.Mechanical properties of dissimilar thickness aluminium alloy weld by single/double pass FSW. J Mater Process Technol 2017; 243: 442–455.
103.
SathariNAAShahLHRazaliAR.Investigation of single-pass/double pass techniques on friction stir welding of aluminium. J Mech Eng Sci2014;
7: 1053–1061.
104.
BonomeECCarlettiCBAlcantaraNGD, et al.
Friction stir welding applied to tailored blanks. Weld Int2007;
21: 279–283.
105.
ZadpoorAASinkeJBenedictusR.Global and local mechanical properties and microstructure of friction stir welds with dissimilar materials and/or thicknesses. Metall Mater Trans A2010;
41: 3365.
106.
AvinashPManikandan MAArivazhaganN, et al.
Friction stir welded butt joints of AA2024 T3 and AA7075 T6 aluminum alloys. Proc Eng2014;
75: 98–102.
107.
TangJShenY.Numerical simulation and experimental investigation of friction stir lap welding between aluminum alloys AA2024 and AA7075. J Alloys Compd2016;
666: 493–500.
