Abstract: Aircraft fuselage structures have reinforcement members in the vicinity of the stringer openings formed in frame members and are rigidly lap joined to a surface region of the frame members by a friction stir weld region. Such aircraft fuselage structural components may thus be provided with plural longitudinally spaced-apart frame members defining a transversal cross-section of an aircraft fuselage section, the frame members having a plurality of stringer holes therethrough, and plural longitudinally oriented stringers each being positioned within a respective one of the stringer holes of the frame member. The reinforcement members are lap joined to corresponding surfaces of frame members in the vicinity of the stringer holes such that the reinforcement members are joined rigidly to the corresponding surfaces of the frame members by a friction stir weld region.

Abstract: Friction stir welding (FSW) processes, systems and the resulting friction stir welded components are disclosed whereby first and second workpieces are welded to one another using a first workpiece having mutually orthogonal structural components and a junction region therebetween which defines a bearing surface of predetermined geometry. A shoulder of a FSW tool may be brought into bearing contact with the bearing surface so that a pin extending from the shoulder of the FSW tool may be advanced into and through the one structural component of the first workpiece at an angle relative thereto so as to thereby form a friction stir weld region between the first and second workpieces. Some preferred embodiments will provide a bearing surface which defines an arcuately concave geometry, in which case the shoulder of the FSW tool defines an arcuately convex geometry conformably mateable with the bearing surface.

Abstract: Friction stir welding (FSW) processes, systems and the resulting friction stir welded components are disclosed whereby first and second workpieces are welded to one another using a first workpiece having mutually orthogonal structural components and a junction region therebetween which defines a bearing surface of predetermined geometry. A shoulder of a FSW tool may be brought into bearing contact with the bearing surface so that a pin extending from the shoulder of the FSW tool may be advanced into and through the one structural component of the first workpiece at an angle relative thereto so as to thereby form a friction stir weld region between the first and second workpieces. Some preferred embodiments will provide a bearing surface which defines an arcuately concave geometry, in which case the shoulder of the FSW tool defines an arcuately convex geometry conformably mateable with the bearing surface.

Abstract: Aircraft fuselage structures have reinforcement members in the vicinity of the stringer openings formed in frame members and are rigidly lap joined to a surface region of the frame members by a friction stir weld region. Such aircraft fuselage structural components may thus be provided with plural longitudinally spaced-apart frame members defining a transversal cross-section of an aircraft fuselage section, the frame members having a plurality of stringer holes therethrough, and plural longitudinally oriented stringers each being positioned within a respective one of the stringer holes of the frame member. The reinforcement members are lap joined to corresponding surfaces of frame members in the vicinity of the stringer holes such that the reinforcement members are joined rigidly to the corresponding surfaces of the frame members by a friction stir weld region.