Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this review article, the current state of understanding and development of the FSW and FSP are addressed. Particular emphasis has been given to: (a) mechanisms responsible for the formation of welds and microstructural refinement, and (b) effects of FSW/FSP parameters on resultant microstructure and final mechanical properties. While the bulk of the information is related to aluminum alloys, important results are now available for other metals and alloys. At this stage, the technology diffusion has significantly outpaced the fundamental understanding of microstructural evolution and microstructure–property relationships.

/pdf/friction-stir-welding-and-processing-3hu3ejo7ub.pdf

Friction Stir Welding and Processing

Progress in structural materials for aerospace systems

Application of modern aluminum alloys to aircraft

We describe four criteria for the selection of alloying elements capable of producing castable, precipitation-strengthened Al alloys with high-temperature stability and strength: these alloying elements must (i) be capable of forming a suitable strengthening phase, (ii) show low solid solubility in Al, (iii) low diffusivity in Al, and (iv) retain the ability for the alloy to be conventionally solidified. With regard to criterion (i), we consider those systems forming Al3M trialuminide compounds with a cubic L12 crystal structure, which are chemically and structurally analogous to Ni3Al in the Ni-based superalloys. Eight elements, clustered in the same region of the periodic table, fulfill criterion (i): the first Group 3 transition metal (Sc), the three Group 4 transition metals (Ti, Zr, Hf) and the four latest lanthanide elements (Er, Tm, Yb, Lu). Based on a review of the existing literature, these elements are assessed in terms of criteria (ii) and (iii), which satisfy the need for a dispersion...

/pdf/criteria-for-developing-castable-creep-resistant-aluminum-7tojhsaie6.pdf

Criteria for developing castable, creep-resistant aluminum-based alloys - A review

The 7XXX series age-hardenable high-strength aluminum alloys find useful applications in the field of aerospace engineering. Constant efforts are being made to tailor the mechanical and corrosion properties of these alloys as per requirements for a particular application. These properties are a function of factors like microstructure, chemical composition and processing parameters. An effort has been made to collate the information available from different studies conducted on alloys Al 7050 and Al 7055. Databases were created to consolidate the information about microstructure, mechanical properties and corrosion behavior for the two alloys. Existing models were utilized to predict strength and fracture toughness for these alloys and these models were validated using experimental values and a qualitative evaluation was made for the corrosion behavior of these alloys. Available data were utilized to prepare maps that are intended to serve as guides to design aluminum alloys with desired combination of properties.

Structure-property correlations in Al 7050 and Al 7055 high-strength aluminum alloys

The design of an aluminum alloy having good strength while maintaining a high resistance to fracture is discussed. Theory suggests that the desired microstructure consists of a small volume fraction of an ultra-fine dispersion of hard particles. In addition to conventional heat treatments, dispersion hardened aluminum alloys have been recently produced by rapid solidification or mechanically alloying and powder metallurgy consolidation. Alloys which can serve as models for mechanistic studies of nucleation of non-coherent phases as well as the basis for a new class of engineering aluminum alloys are identified.

E. Hornbogen

Papers

Overview no. 102 Theory assisted design of high strength low alloy aluminum