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The use of friction stir processing to locally modify the microstructure to enhanced formability has the potential to alter the manufacturing of structural shapes. There is enough research to put together a short monograph detailing the fundamentals and key findings. One example of conventional manufacturing technique for aluminum alloys involves fusion welding of 5XXX series alloys. This can be replaced by friction stir welding, friction stir processing and forming. A major advantage of this switch is the enhanced properties. However qualification of any new process involves a series of tests to prove that material properties of interest in the friction stir welded or processed regions meet or exceed those of the fusion welded region (conventional approach). This book will provide a case study of Al5083 alloy with some additional examples of high strength aluminum alloys.

• Demonstrates how friction stir processing enabled forming can expand the design space by using thick sheet/plate for applications where pieces are joined because of lack of formability
• Opens up new method for manufacturing of structural shapes
• Shows how the process has the potential to lower the cost of a finished structure and enhance the design allowables

This book describes the fundamentals and potential applications of ‘friction stir superplasticity for unitized structures’. Conventional superplastic forming of sheets is limited to the thickness of 3 mm because the fine grained starting material is produced by rolling. Friction stir superplasticity has grown rapidly in the last decade because of the effectiveness of microstructural refinement. The thickness of the material remains almost constant, and that allows for forming of thick sheets/plates, which was not possible before. The field has reached a point where designers have opportunities to expand the extent of unitized structures, which are structures in which the traditional primary part and any supporting structures are fabricated as a single unit. With advanced optimization and material considerations, this class of structures can be lighter weight and more efficient, making them less costly, as well as mechanically less complex, reducing areas of possible failure.

• Discusses how friction stir processing allows selective microstructural refinement without thickness change
• Demonstrates how higher thickness sheets and plates can be superplastically formed
• Examples are presented for aluminum, magnesium and titanium alloys
• Covers the production of low-cost unitized structures by selectively processing cast sheets/plates

This book will summarize research work carried out so far on dissimilar metallic material welding using friction stir welding (FSW). Joining of dissimilar alloys and materials are needed in many engineering systems and is considered quite challenging. Research in this area has shown significant benefit in terms of ease of processing, material mixing, and superior mechanical properties such as joint efficiencies. A summary of these results will be discussed along with potential guidelines for designers.

• Explains solid phase process and distortion of work piece
• Addresses dimensional stability and repeatability
• Addresses joint strength
• Covers metallurgical properties in the joint area
• Covers fine microstructure
• Introduces improved materials use (e.g., joining different thicknesses)
• Covers decreased fuel consumption in light weight aircraft
• Addresses automotive and ship applications

Friction Stir Welding of High Strength 7XXX Aluminum Alloys is the latest edition in the Friction Stir series and summarizes the research and application of friction stir welding to high strength 7XXX series alloys, exploring the past and current developments in the field.

Friction stir welding has demonstrated significant benefits in terms of its potential to reduce cost and increase manufacturing efficiency of industrial products in transportation, particularly the aerospace sector. The 7XXX series aluminum alloys are the premium aluminum alloys used in aerospace. These alloys are typically not weldable by fusion techniques and considerable effort has been expended to develop friction stir welding parameters. Research in this area has shown significant benefit in terms of joint efficiency and fatigue performance as a result of friction stir welding. The book summarizes those results and includes discussion of the potential future directions for further optimization.

• Offers comprehensive coverage of friction stir welding of 7XXX series alloys
• Discusses the physical metallurgy of the alloys
• Includes physical metallurgy based guidelines for obtaining high joint efficiency
• Summarizes the research and application of friction stir welding to high strength 7XXX series alloys, exploring the past and current developments in the field