The primary FSW research work will be performed in the 3,930 sq. ft. high bay Advanced Joining laboratory. The driving force behind the FSW process is an MTS ISTIR PDS 5-axis Friction Stir Welding Machine. This machine has a 120-inch x 25-inch x 40-inch work envelope with the capability to join structures with complex curvatures.

Since its development, the FSW process has shown itself to have benefits over established mechanical joining methods. Significant interest has been shown in its comparison to current joining techniques for aircraft structures, particularly in relation to the design and manufacturing benefits that the process affords over the current methods. The advantages over the standard riveting and fusion welding processes for aluminum include improved joint strength, reduction in manufacturing time, reduced complexity of manufacturing process and reduction in parts count and weight.

"The FSW process could potentially provide significant improvement in the structural integrity and damage tolerance of metallic aircraft structures," Dale Cope, director of the Advanced Joining Laboratory said. "By eliminating fastener holes in a joint, the primary cause of cracks in mechanically fastened components has been removed from the airframe design, thereby likely improving its overall structural integrity and airworthiness."

The National Institute for Aviation Research hopes that the creation of this laboratory will provide them with the leverage to achieve greater advancements in the implementation of this technology into industry.

The lab was developed in part by the NIAR/Industry/State (NIS) program and the Federal Aviation Administration. Initially, the lab will be utilized by industry partners participating in the NIS program and by the FAA. The lab will be open to new clients next summer.