Evaluation of Friction Stir Welding for Sheet Metal Resonant Structures

In aerospace and transportation industries, severe problems are related to fatigue failure. Aluminium is frequently used in these industries to optimize the solidity and minimise the weight of the structures. Nevertheless, the fatigue life of aluminium alloys is limited and specific efforts have to be made to reduce the vibratory stresses in the mechanical parts. When riveted, the life of the sheet metal structures can be increased compared to welded structures, due to the energy dissipated by the friction between the rivets and the sheet metal and the sheets themselves. In the past decade, a new tool was developed to assemble aluminium structures; the friction stir welding. With this new technique, fatigue life of the aluminium welded joints can be increased by a factor from two to ten. However, less energy can be damped by the friction between the components and increased vibratory stresses may occur. In this investigation, the potential of the friction stir welding to create damped aluminium sheet metal structures is evaluated.