Application of Aluminum Alloy Stirring Friction Welding in Aerospace

As the research on friction stir welding progressed further, the friction stir welding equipment gradually moved from the laboratory to commercial use. TWI applied this technology to produce three 2000 series aluminum alloy spacecraft fuel tanks for Boeing; Lockheed, USA. Martin, Boeing-McDow, Rockwell Group, Edison Welding Institute and many other organizations are currently working on the research, application evaluation and development of friction stir welding. Structures suitable for welding with FSW technology in the aerospace industry include: skins for military or civil aircraft, low temperature fuel tanks for spacecraft, aircraft fuel tanks, auxiliary tanks for military aircraft, military or scientific detection rockets, etc.; Lockheed, USA. Martin Aerospace used this technology to weld cryogenic vessels that store liquid oxygen outside the space shuttle; the Marshall Space Flight Center has also used this technology to weld large cylindrical vessels.

Boeing invested millions of dollars to build a large, dedicated, agitated friction welder for large, low-temperature fuel containers for Delta launch vehicles. BAE Airbus is testing method, performance and feasibility of FSW technology for production. For medium and large commercial aircraft, the agitator friction welder is manufactured by GRAWFORD-SWIFT, located in Helix, and is said to be the most powerful welder in Europe. The US ECLIPSE (Lunar Eclipse) airline will use FSW to build a medium-sized aircraft with a length of 10.86m and a wingspan of 11.88m. Figure 1 shows the E500 new energy-saving small jet high-tech aircraft developed by ECLIPSE in the United States. The company estimates that the FSW can reduce the assembly time of the ribs and frames on the fuselage wall panel by 80%, reducing the aircraft cost to $837,000. The main structural parts and skins of the aircraft are all manufactured by the latest international connection technology, agitating friction welding technology. The fuselage of the passenger aircraft is basically made by friction stir welding, including aircraft skin, ribs and strings. Support, aircraft floor and assembly of structural parts.

The application of friction stir welding is mainly used to improve production efficiency and reduce manufacturing cost. The agitating friction welding process for aviation structural parts is jointly developed by TWI and American ALCOA company, and then applied to the welding of ECLIPSE500 aircraft structural parts. In September 2000, the company passed the preliminary design evaluation and certification of the Aircraft Safety Committee. In June 2001, the feasibility of aircraft manufacturing for friction stir welding was determined. In 2001, the structure of the friction stir welding aircraft was manufactured. The first in June 2002. Flying, and from June 29th to July 1st to show the public that this new type of aircraft has hundreds of customers vying to order this new modest, cut-off business aircraft.

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