LAUSR

Purpose Presently, the materials used in light combat aircraft structures are aluminium alloys and composites. These structures are joined together through riveted joints. The weight of these rivets for the entire aircraft is nearly one ton. In addition to weight, the riveted connection requires a lot of tools, equipments, fixtures and manpower, which makes it an expensive and time-consuming process. Moreover, Al alloy is also welded using tungsten inert gas (TIG) welding process by proper control of process parameters. This process has limitations such as porosity, alloy segregation and hot cracking. To overcome the above limitations, an alternative technology is required. One such technology is friction stir welding (FSW), which can be successfully applied for welding of aluminium alloy in LCA structures. Therefore, this paper aims to compare the load carrying capabilities of FSW joints with TIG welded and riveted joints. Design/methodology/approach FSW joints and TIG welded joints were fabricated using optimized process parameters, followed by riveted joints using standard shop floor practice in the butt and lap joint configurations. Findings The load-carrying capabilities of FSW joints are superior than those of other joints. FSW joints exhibited 75 per cent higher load-carrying capability compared to the riveted joints and TIG-welded joints. Practical implications From this investigation, it is inferred that the FSW joint is suitable for the replacement of riveted joints in LCA and TIG-welded joints. Originality/value Friction stir butt joints exhibited 75 per cent higher load-carrying capability than riveted butt joints. Friction stir welded lap joints showed 70 per cent higher load-carrying capability than the riveted lap joints. Friction stir butt joints yielded 41 per cent higher breaking load capabilities than the TIG-welded butt joints. Moreover, Friction stir lap weld joints have 57 per cent more load-carrying capabilities than the TIG-welded lap joints.