Innovative techniques for joining and processing of some aluminum alloys used in the aircraft industry

The continuous development of various cutting-edge fields of science and technology, including the aerospace industry, is advancing at an accelerated pace. To meet current technical, economic, and environmental demands, new ecological and efficient material joining and processing techniques have been developed, aiming to replace some of the commonly used industrial procedures. For aluminum alloys, friction-based joining and processing methods with a rotating tool element are presented in this paper, with potential applications in the aerospace industry. Data is provided on Friction Stir Welding (FSW), known for its ability to produce high-quality joints without compromising the structural integrity of materials, highlighting its advantages over traditional welding methods. The diversity of metallic materials, their characteristics and properties, as well as the technical requirements of different applications, have led to the development of variants of the friction stir welding process, one of which is Submerged (underwater) Friction Stir Welding (SFSW). Data on FSW and SFSW welding as well as several aluminum alloys that can be used in the aerospace industry are included in the paper. The paper also discusses ISIM's approaches in the FSW/SFSW domain for aluminum alloys EN AW 6082 and EN AW 7075 that are applicable to the aerospace industry because of their relevance and interest. The positive outcomes show that FSW and SFSW welding can be developed for a variety of metallic materials. The goal of ISIM’s current and future research is to apply the principles of the FSW/SFSW process to the FSP/SFSP processing of non-ferrous alloys, which can be used in a variety of industries.