Challenges in joining of unequal thickness materials for aerospace applications: A review

Abstract

The increasing industrial demand to reduce structural weight, optimize structural strength, and high performance has led to the increasing use of tailors welded blanks. However, the joining of tailors welded blanks is an issue of concern to researchers owing to the difference in thickness between the materials in addition to the difference in physical and chemical properties in the case of dissimilar materials. These challenges in joining of tailors welded blanks are conquered by a recent solid phase joining process known as friction stir welding. This review work covers different methods of joining unequal thickness similar/dissimilar (or tailors welded blanks) aircraft materials in different joint configurations along with the challenges and failure modes encountered in these joining processes. From this article researchers and industrialists can take advantage and conquer relative limitations in order to meet the future challenges for joining of similar/dissimilar aircraft materials with unequal thickness