Manufacture of Thin-Walled Axisymmetric Components by Friction Stir Welding and Spinning of Al-Li Alloy

A novel hybrid manufacturing technique combining friction stir welding and spinning provides a promising approach to forming large-diameter thin-walled axisymmetric components while minimizing process scrap. By integrating experimental and numerical methods, the feasibility of the hybrid manufacturing technique for producing thin-walled axisymmetric components with the 2195 Al-Li alloy was explored. The results indicate that the welding seam of the spun components restricts plastic deformation, which leads to flange swing. The movement of the welding seam occurs during spinning, and the movement direction is consistent with the rotation direction of the spun components. The microhardness of the components in the welding zone was found to increase by 21% on average after spinning. Moreover, the yield strength in the welding zone increased by over 60% and the tensile strength by over 12%. These results suggest that the hybrid manufacturing technique is a feasible way to produce large-diameter thin-walled axisymmetric components. Since the process scraps can be re-utilized using this method, it thus provides a potential route for sustainability in the recycling and remanufacturing of aluminum alloys.