The Influence of Friction Stir Welding Process Idealization on Residual Stress and Distortion Predictions for Future Airframe Assembly Simulations

The ability to accurately predict residual stresses and resultant distortions is a key product from process assembly simulations. Assembly processes necessarily consider large structural components potentially making simulations computationally expensive. The objective herein is to develop greater understanding of the influence of friction stir welding process idealization on the prediction of residual stress and distortion and thus determine the minimum required modeling fidelity for future airframe assembly simulations. The combined computational and experimental results highlight the importance of accurately representing the welding forging force and process speed. In addition, the results emphasize that increased CPU simulation times are associated with representing the tool torque, while there is potentially only local increase in prediction fidelity.

Comparative growth rates and internal banding periodicity of maerl species (Corallinales, Rhodophyta) from northern Europe

Maerl is a type of rhodolith, found in ecologically important beds of high conservation value; a major conservation objective is to establish growth rates. Maerl shows internal banding of controversial periodicity that may contain a high-resolution record of palaeoceanographic-palaeoclimatic data. To investigate growth rates and banding periodicity, we used the vital stain Alizarin Red in combination with scanning electron microscopy (SEM). Three maerl species, Phymatolithon calcareum, Lithothamnion corallioides and L. glaciale, were collected from maerl beds in Ireland. Following staining, maerl was grown in three controlled temperature treatments and at two depths in the field (P. calcareum only), with Corallina officinalis as a control for the stain. Alizarin Red was shown to be a suitable marker for growth in European maerl species and for C. officinalis. The average tip growth rate of P. calcareum from Northern Ireland at 10 m depth and under constant laboratory conditions was c. 0.9 mm yr(-1), double the rates observed at 5 m depth and in L. corallioides. Our measurements and re-examination of reported data allow us to conclude that the three most abundant maerl species in Europe grow about 1 (0.5-1.5) mm per tip per year under a wide range of field and artificial conditions. Internal banding in temperate European maerl revealed by SEM is a result of regular changes in wall thickness; the approximately monthly periodicity of bands in field-grown specimens is consistent with previous suggestions that they may be lunar. The potential for maerl banding to be a high-resolution record of palaeoclimatic and palaeoenvironmental change could be realized with this vital stain in conjunction with isotopic or microgeochemical analyses.

Buckling/post-buckling strength of friction stir welded aircraft stiffened panels

Assembling aircraft stiffened panels using friction stir welding offers potential to reduce fabrication time in comparison to current mechanical fastener assembly, making it economically feasible to select structurally desirable stiffener pitching and novel panel configurations. With such a departure from the traditional fabrication process, much research has been conducted on producing strong reliable welds, with less examination of the impact of welding process residual effects on panel structural behaviour and the development of appropriate design methods. This article significantly expands the available panel level compressive strength knowledge, demonstrating the strength potential of a welded aircraft panel with multiple lateral and longitudinal stiffener bays. An accompanying computational study has determined the most significant process residual effects that influence panel strength and the potential extent of panel degradation. The experimental results have also been used to validate a previously published design method, suggesting accurate predictions can be made if the conventional aerospace design methods are modified to acknowledge the welding altered panel properties.