Fsw Technique Research On Aluminium Alloy Car Body Sidewall Of Mass Transit Train

Friction stir welding (FSW) is a relatively new solid joining process. Owing to itsadvantages in joining the alloys with low melting point, FSW is a promising applicationin spacecraft and train manufacture. Most studies on FSW are focused on the butt jointof sheets. However, the study on the joint of aluminum profile with complicatedstructure is limited.The optimal FSW process parameters of the3.5-mm-thick6005A-T6aluminumalloy are obtained as follows: the rotational speed of welding tool is1500r/min, weldingspeed is500mm/min and the length of pin is4.2mm. In this study, the boss design isemployed in order to solve the problem of the weld carrying area reducing, and thecarrying capability of the joint is also improved. The optimal size of the boss is6.5×0.4mm.The good-quality side wall plants are obtained by using the optimal weldingparameters. The polishing time is the same as that of the original joint structure withoutthe boss. The good weld performance of the side wall plant is obtained by friction stirwelding process. The structure deformation after welding is small and the overallflatness of the side wall is only2mm. The static strength of the car body is tested afterthe sidewall plant is fixed in the car body, and the test result shows that the strength andstiffness of the car body, whose sidewall is made by FSW process, meet therequirements for the standard EN12663.