Friction Stir Welded Aircraft Structure for Low-Drag Assembly
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Solution Overview
Problem
Traditional methods of joining aircraft components, such as bolting, increase the weight and aerodynamic drag of aircraft structures while being labor-intensive and costly, especially for monolithic structures with multiple aerodynamic surfaces.
Innovation Solution
Friction stir welding is used to join monolithic aircraft structures, forming continuous or intermittent welds between body and cover components, as well as between these components and optional stiffeners, to create a lightweight and drag-reduced aerodynamic surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining methods such as bolting are used to attach cover components to body components, then the structural strength and reliability are improved, but the weight of the aircraft structure increases and aerodynamic drag is introduced
Solution Approach 1:
The patent merges the cover component and body component into a single monolithic structure through friction stir welding, eliminating the need for separate fasteners and bonding materials. This combining approach maintains structural strength while removing the additional weight associated with traditional joining methods.
Solution Approach 2:
The invention extracts and removes the fasteners and bonding materials from the joining process, replacing them with a direct friction stir welded joint. This extraction eliminates the harmful factors of additional weight and aerodynamic drag while preserving the structural integrity through the welded connection.
2Reliability
If traditional joining methods such as bolting are used to attach cover components to body components, then the structural strength and reliability are improved, but the aerodynamic drag increases due to additional components and surface disruption
Solution Approach 1:
By merging the cover and body into a monolithic structure, the invention eliminates protruding fasteners and reduces surface discontinuities that cause aerodynamic drag. The continuous surface created by friction stir welding minimizes turbulence and drag while maintaining structural strength.
Solution Approach 2:
The friction stir welded joint creates a localized strong connection between the cover and body components, providing structural strength only where needed at the joint interface, while the surrounding aerodynamic surfaces remain smooth and continuous to minimize drag.
3Ease of operation
If traditional joining methods such as bolting are used to attach cover components to body components, then the ease of assembly is improved, but the manufacturing cost and labor requirements increase
Solution Approach 1:
The invention replaces the mechanical fastening system (bolts, nuts, fasteners) with a friction stir welding process that creates a metallurgical bond. This substitution eliminates the need for multiple fasteners and assembly steps, reducing labor requirements and manufacturing cost while maintaining assembly capability through the welding process.
4Weight of moving object
If friction stir welding is used to join monolithic aircraft structures, then the weight and aerodynamic drag are reduced, but the manufacturing complexity and process difficulty increase
Solution Approach 1:
The friction stir welding process is self-service in that it generates its own heat through friction between the rotating tool and the workpiece, eliminating the need for external heating equipment. The process automatically creates the weld joint through mechanical friction and stirring action, reducing the complexity of manufacturing equipment while achieving weight reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces assembly expenses, weight, and aerodynamic drag by forming a strong, lightweight monolithic structure with minimal additional surface disruption, enhancing the structural integrity and aerodynamic performance of aircraft components.
Implementation Method 1
friction stir welding is used to join monolithic aircraft structures
Implementation Method 2
friction stir welding is used to join monolithic aircraft structures, forming continuous or intermittent welds between body and cover components
Data Source
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AI summary
A method (300, Fig.8) of forming a monolithic aircraft structure having multiple aerodynamic surfaces includes forming a body component (210) to have a body skin (214) defining a body skin outer surface (216), and a body side wall (218) integrally formed with the body skin (214) and defining a body mating surface (226), the body skin outer surface (216) providing a first aerodynamic surface. A cover component (212) is formed to have a cover mating surface (240) and a cover outer surface (242) opposite the cover mating surface (240), the cover outer surface (242) defining a second aerodynamic surface. The body component (210) is positioned relative to the cover component (212) so that the body mating surface (226) engages the cover mating surface (240). At least portions of the cover mating surface (240) are friction stir welded to the body mating surface (226) to form friction stir welded joints (250) between the body component (210) and the cover component (212).