Friction Stir Welding of Aerospace Materials

AFRL scientists are studying a unique metal joining process— friction stir welding (FSW)—for building major structural assemblies. FSW is a solid-state welding process that forces a spinning tool along the joint line, heating the abutting components by friction and producing a weld joint formed by strong plastic mixing (stirring) of the two components' constituent materials. FSW promises to be a highly efficient and cost- effective alternative to the conventional fusion welding routinely used for joining structural alloys on military and civilian aircraft.