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Influence of Friction Stir Weld Seam Distribution on Spun Formed Workpieces

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Abstract

Employing friction stir welding (FSW) technology to join small plate blanks into larger ones, followed by a spinning process, adeptly surpasses the dimensional constraints of traditionally rolled plate blanks. This innovative approach paves the way for the fabrication of large and super-sized thin-walled rotary components, with significant implications in the aerospace sector. In this methodology, the number and layout of welds critically influence the precision of forming in spun workpieces, which could be pivotal in the success of spun tailor-welded blanks (TWBs). Consequently, dedicated experimental research into the spin forming of TWBs, varying in weld numbers and configurations, is essential. This investigation employed annealed 2195 Al–Li alloy plates as the material for experimentation. Four types of blanks with varying weld distributions and increasing weld numbers were designed, prepared through multiple FSW processes, followed by spinning. Comprehensive measurements of weld torsion angles, surface morphology, thickness variations, and forming accuracy of the workpieces post-spinning were conducted. The results show that with the increase of the number of welds, the weld torsion angle of the workpiece after spinning decreases. The spinning process can significantly reduce the surface morphology of the weld area. The thickness of the weld area is thinner than that of the non-weld area, and the superposition of the welds will aggravate the thickness reduction. In addition, the accuracy deviation of the workpiece mainly occurs in the initial and final stages of spinning forming. A negative accuracy deviation occurs at the beginning of the spinning, and a positive accuracy deviation is observed at the end of the spinning stage. In the spinning stage, the welding area appears slight bulge. As the number of welding seams increases, the accuracy of the workpiece decreases.

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Acknowledgements

The National Natural Science Foundation of China (Grant No. 52301090); Shandong Province ZR2023QE275 provided research facilities for this work; Shandong Province 2019GGX102023 key research and development plan project.

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  1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266525, China

    Shouyi Sun, Jin Wang, Bo Gao, Gaowei Cao & Shuai Zhang

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  1. Shouyi Sun
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Correspondence to Jin Wang.

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Sun, S., Wang, J., Gao, B. et al. Influence of Friction Stir Weld Seam Distribution on Spun Formed Workpieces. Int. J. Precis. Eng. Manuf. (2024). https://doi.org/10.1007/s12541-024-00994-w

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