US20050210820A1 - Frame and method for fabricating the same - Google Patents
Frame and method for fabricating the same Download PDFInfo
- Publication number
- US20050210820A1 US20050210820A1 US10/807,136 US80713604A US2005210820A1 US 20050210820 A1 US20050210820 A1 US 20050210820A1 US 80713604 A US80713604 A US 80713604A US 2005210820 A1 US2005210820 A1 US 2005210820A1
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- frame member
- frame
- chord
- extension
- friction stir
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- Abandoned
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- 238000000034 method Methods 0.000 title claims description 27
- 238000003756 stirring Methods 0.000 claims abstract description 22
- 238000003466 welding Methods 0.000 claims description 12
- 238000004381 surface treatment Methods 0.000 claims description 11
- 239000005002 finish coating Substances 0.000 claims description 10
- 238000001125 extrusion Methods 0.000 description 14
- 238000005304 joining Methods 0.000 description 8
- 238000010276 construction Methods 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 238000000576 coating method Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000007743 anodising Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
- B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
- B64C1/064—Stringers; Longerons
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C3/06—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web
- E04C3/07—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web at least partly of bent or otherwise deformed strip- or sheet-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/38—Arched girders or portal frames
- E04C3/40—Arched girders or portal frames of metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0408—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section
- E04C2003/0413—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section being built up from several parts
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
- E04C2003/046—L- or T-shaped
Definitions
- This invention relates to frames and methods for fabricating the same.
- Monocoque construction is formed of a plurality of ring-like frames and an outer panel that covers these frames so that the outer panel, having a small rigidity in itself, is reinforced by the frames, thereby implementing a light-weight and rigid structure.
- an outer panel 101 is provided with not only frames 102 but also stringers 103 that extend in the longitudinal direction of the body and intersect with the frames 102 .
- Semi-monocoque construction thus implements a more rigid structure by both the frames 102 and the stringers 103 .
- the conventional frame 102 is formed of an outer chord 105 of T-shaped section, a web 106 like a flat plate, and an inner chord 107 of L-shaped section, which are joined together by a large number of fasteners 108 .
- the conventional frame 102 is fabricated in the following manner.
- an outer chord 105 , a web 106 and an inner chord 107 are fabricated in separate steps, subjected individually to surface treatment (see steps S 102 , S 202 and S 302 ), and subjected individually to finish coating (see steps S 103 , S 203 and S 303 ). Then, these members are assembled (see step S 104 ). In assembly, an extension of the outer chord 105 and the web 106 are overlapped, and then fastened along their rims by a large number of fasteners 108 . Similarly, the web 106 and the inner chord 107 are also overlapped and fastened along their rims by a large number of fasteners 108 .
- the conventional frame 102 is fabricated in this manner.
- the conventional frame 102 requires many fasteners 108 for the joining between the outer chord 105 and the web 106 and for the joining between the web 106 and the inner chord 107 . Therefore, the weight of the frame 102 is increased by those of the fasteners 108 . Furthermore, the joinings using the fasteners 108 involve the provision of the overlapping portions of the outer chord 105 , the web 106 and the inner chord 107 . Therefore, the weight of the frame 102 is also increased by those of the overlapping portions.
- the surface treatment process (see steps S 102 , S 202 and S 302 ) and the finish coating process (see steps S 103 , S 203 and S 303 ) are necessary for each of the outer chord 105 , the web 106 and the inner chord 107 .
- the surface treatment and finish coating processes necessary as a preliminary stage for the assembly process must be carried out for each of the outer chord 105 , the web 106 and the inner chord 107 . This invites an elongated lead time.
- the present invention has been made in view of the foregoing points, and therefore its object is to provide a frame light in weight and small in the number of process steps and a method for fabricating the same.
- a frame comprises: an outer frame member of T-shaped section having an extension extending inwardly; and an inner frame member having a flat portion abutting against the extension of the outer frame member, wherein the outer frame member and the inner frame member are friction stir welded together with the edge of the extension of the outer frame member abutted against the edge of the flat portion of the inner frame member.
- the frame according to the first aspect is characterized in that the inner frame member is formed of two or more frame members friction stir welded together with one abutted against another.
- a method for fabricating a frame comprises the steps of: preparing an outer frame member of T-shaped section having an extension extending inwardly; preparing an inner frame member having a flat portion abutting against the extension of the outer frame member; and friction stir welding the outer frame member and the inner frame member with the edge of the extension of the outer frame member abutted against the edge of the flat portion of the inner frame member.
- the method according to the third aspect is characterized in that the step of preparing an inner frame member comprises the step of friction stir welding two or more frame members with one abutted against another.
- the method according to the third or fourth aspect is characterized by further comprising, after friction stir welding the outer frame member and the inner frame member, the step of subjecting the outer and inner frame members together to surface treatment or finish coating.
- the inner and outer frame members are joined together by friction stir welding, and therefore no fasteners are needed for the joining.
- the frame can be reduced in weight by the weight corresponding to fasteners that would conventionally be required.
- the inner and outer frame members are joined together with one abutted against the other, no overlapping portion between both the members is needed. Therefore, the frame of the invention can have a smaller weight than the conventional frame by the weight corresponding to the overlapping portions.
- the inner frame member is formed by butting two or more frame members together. Therefore, the frame diametral dimension (or lateral width) can be increased. Since the frame members constituting the inner frame member are friction stir welded together with one abutted against another, there is no need for fasteners for the joining of them and also no need for their overlapping portions. Therefore, the inner frame member can be reduced in weight.
- the inner and outer frame members need not be subjected individually to surface treatment or finish coating. Therefore, the number of process steps and the lead time can be reduced.
- FIG. 1 is a perspective view of a frame.
- FIG. 2 is a flow chart of a method for fabricating a frame.
- FIG. 3A is a perspective view showing an extrusion for an outer chord.
- FIG. 3B is a perspective view showing an outer chord.
- FIG. 4A is a perspective view showing an extrusion for an inner chord.
- FIG. 4B is a perspective view showing an inner chord.
- FIG. 5 is a perspective view of another frame.
- FIG. 6 is a perspective view of still another frame.
- FIG. 7 is a flow chart of another method for fabricating a frame.
- FIG. 8 is a perspective view of a body.
- FIG. 9A is a perspective view of a conventional frame.
- FIG. 9B is a cross-sectional view of the conventional frame.
- FIG. 10 is a flow chart showing a method for fabricating a conventional frame.
- a frame 1 according to this embodiment is used as a frame in an airplane body of monocoque or semi-monocoque construction.
- the entire structure of the monocoque or semi-monocoque body is well known, and therefore explanation thereof is not given herein (see FIG. 8 ).
- FIG. 1 shows the structure of the frame 1 .
- the frame 1 is formed of an outer chord 2 of T-shaped section having an extension 4 extending inwardly, and an inner chord 3 of L-shaped section having a flat portion 5 .
- the outer chord 2 and the inner chord 3 are made from aluminum.
- the outer chord 2 and the inner chord 3 are formed to have an elongate shape, and are curved along the inner periphery of the airplane body.
- the inner edge of the outer chord 2 and the outer edge of the inner chord 3 have the same curvature.
- the outer chord 2 and the inner chord 3 are friction stir welded together with the edge of the extension 4 abutted against the edge of the flat portion 5 .
- the extension 4 and the flat portion 5 are welded continuously on their seam, whereby the frame 1 are formed with a joint 6 extending along its curvature.
- the frames intersect with stringers and an outer panel is provided on the body surface sides of these members.
- the frame and the stringer are equal in that they act as reinforcing members.
- Both the members are different in that the stringer is a member extending along the longitudinal direction of the body, while the frame is a member orthogonal to the longitudinal direction of the body and extending along the inner periphery of the body.
- the frame is actually designed and fabricated from a different view point from the fabrication of the stringer.
- step S 1 a straight extrusion 10 (see FIG. 3A ) of T-shaped section is fabricated by extruding or drawing. Then, in step S 2 , the extrusion 10 is bent by stretch forming. In this manner, an outer chord 2 (see FIG. 3B ) is prepared from the extrusion 10 . Thereafter, heat treatment is conducted on the prepared outer chord 2 as necessary to complete the outer chord 2 (see step S 3 ). It is needless to say that instead of fabricating an extrusion 10 , a standard extrusion can be purchased and an outer chord 2 can be prepared from the purchased extrusion.
- an inner chord 3 For the preparation of an inner chord 3 , a straight extrusion 11 (see FIG. 4A ) of L-shaped section is first fabricated by extruding or drawing in step S 4 . Then, in step S 5 , the extrusion 11 is bent by stretch forming. In this manner, an inner chord 3 (see FIG. 4B ) is prepared from the extrusion 11 . Thereafter, heat treatment is conducted on the prepared inner chord 3 as necessary to complete the inner chord 3 (see step S 6 ). Also for the inner chord 3 , it is needless to say that instead of fabricating an extrusion 11 , a standard extrusion can be purchased and an inner chord 3 can be prepared from the purchased extrusion.
- the fabrication process for an outer chord 2 in steps S 1 to S 3 and the fabrication process for an inner chord 3 in steps S 4 to S 6 are individually conducted. Therefore, both the fabrication processes may be carried out concurrently or one after the other.
- step S 7 the completed outer chord 2 and inner chord 3 are friction stir welded together with the extension 4 of the outer chord 4 abutted against the flat portion 5 of the inner chord 3 .
- the outer chord 2 and the inner chord 3 are welded continuously to draw a curve on their seam.
- welding points of the friction stir welding there is no particular limit to welding points of the friction stir welding.
- both the chords may be welded at discrete points on the seam, or may be welded discontinuously to draw a dotted curve.
- step S 8 the outer and inner chords 2 and 3 are together subjected to surface treatment.
- anodizing is conducted as surface treatment to form a coating on the surface of the frame 1 .
- step S 9 the outer and inner chords 2 and 3 are together subjected to finish coating in step S 9 , thereby completing the frame 1 (step S 10 ).
- the flange 9 may be formed with cutaways (flange trims) 7 or holes (not shown).
- the flat portion (web) 5 may be formed with holes 8 . In these cases, the formation of cutaways or holes is carried out after the friction stir welding in step S 7 .
- the frame 1 according to this embodiment can be reduced in weight because of the absence of fasteners. Furthermore, the outer and inner chords 2 and 3 are joined with one abutted against the other, and therefore they need not be overlapped with each other. As a result, the frame 1 of this embodiment can have a smaller weight than the conventional frame by the weight corresponding to the overlapping portions.
- Each of surface treatment and finish coating can be conducted on the outer and inner chords 2 and 3 at one time after the joining of them, and need not be conducted on each of them. Therefore, the number of process steps for the outer and inner chords 2 and 3 can be extensively reduced. This results in shortened lead time.
- This frame 15 includes the web 12 between the outer chord 2 and the inner chord 3 , so that the frame diametral dimension (or the flame lateral width) is increased.
- the outer chord 2 , the inner chord 3 and the web 12 are all made of aluminum.
- the outer chord 2 constitutes an outer frame member, while the inner chord 3 and the web 12 constitute an inner frame member.
- FIG. 7 shows a flow chart of a method for fabricating a frame 15 .
- the outer and inner chords 2 and 3 are fabricated in the same manner as described above (see steps S 1 to S 3 and S 4 to S 6 ).
- the web 12 is formed by cutting a flat plate (sheet metal) of aluminum into a predetermined shape.
- the outer chord 2 and the web 12 are friction stir welded together with the extension 4 of the outer chord 2 abutted against one edge of the web 12
- the web 12 and the inner chord 3 are also friction stir welded together with the other edge of the web 12 abutted against one edge of the inner chord 3 (step S 7 ).
- the welded outer chord 2 , web 12 and inner chord 3 are together subjected to surface treatment (step S 8 ) and then finish coating (step S 9 ), thereby implementing a frame 15 .
- the number of webs 12 provided is not restricted to one. If necessary, two or more webs can be abutted and friction stir welded together to further increase the frame diametral dimension.
- the material for the frames 1 and 15 is not restrictive, and metals other than aluminum can be used for the frames 1 and 15 .
- the frames 1 and 15 are not used only for airplane bodies, but may be used for the other parts (for example, wings). Furthermore, the applications of the frame according to the present invention include not only airplanes but also ships, vessels, vehicles and other structures such as buildings.
- the frames 1 and 15 are not restrictive in their shape, but can take various shapes.
- the frames 1 and 15 may have a bent shape or a linear shape.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Aviation & Aerospace Engineering (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
A frame 1 is formed of an outer chord 2 of T-shaped section having an extension 4 extending inwardly, and an inner chord 3 having a flat portion 5 abutting against the extension 4 of the outer chord 2. The extension 4 of the outer chord 2 and the flat portion 5 of the inner chord 3 are friction stir welded together with one abutted against the other.
Description
- (a) Field of the Invention
- This invention relates to frames and methods for fabricating the same.
- (b) Description of the Related Art
- For structures required to have both light weight and rigidity, such as airplane bodies and wings, so-called monocoque construction or semi-monocoque construction are traditionally employed (see, for example, Japanese Unexamined Patent Publication No. 5-286496). Monocoque construction is formed of a plurality of ring-like frames and an outer panel that covers these frames so that the outer panel, having a small rigidity in itself, is reinforced by the frames, thereby implementing a light-weight and rigid structure. In semi-monocoque construction, as shown in
FIG. 8 , anouter panel 101 is provided with not onlyframes 102 but also stringers 103 that extend in the longitudinal direction of the body and intersect with theframes 102. Semi-monocoque construction thus implements a more rigid structure by both theframes 102 and thestringers 103. - As shown in
FIGS. 9A and 9B , theconventional frame 102 is formed of anouter chord 105 of T-shaped section, aweb 106 like a flat plate, and aninner chord 107 of L-shaped section, which are joined together by a large number offasteners 108. Theconventional frame 102 is fabricated in the following manner. - First, as shown in steps S101, S201 and S301 in
FIG. 10 , anouter chord 105, aweb 106 and aninner chord 107 are fabricated in separate steps, subjected individually to surface treatment (see steps S102, S202 and S302), and subjected individually to finish coating (see steps S103, S203 and S303). Then, these members are assembled (see step S104). In assembly, an extension of theouter chord 105 and theweb 106 are overlapped, and then fastened along their rims by a large number offasteners 108. Similarly, theweb 106 and theinner chord 107 are also overlapped and fastened along their rims by a large number offasteners 108. Theconventional frame 102 is fabricated in this manner. - As described above, the
conventional frame 102 requiresmany fasteners 108 for the joining between theouter chord 105 and theweb 106 and for the joining between theweb 106 and theinner chord 107. Therefore, the weight of theframe 102 is increased by those of thefasteners 108. Furthermore, the joinings using thefasteners 108 involve the provision of the overlapping portions of theouter chord 105, theweb 106 and theinner chord 107. Therefore, the weight of theframe 102 is also increased by those of the overlapping portions. - Furthermore, the surface treatment process (see steps S102, S202 and S302) and the finish coating process (see steps S103, S203 and S303) are necessary for each of the
outer chord 105, theweb 106 and theinner chord 107. This increases the number of process steps, leading to much expense in time and cost. Furthermore, the surface treatment and finish coating processes necessary as a preliminary stage for the assembly process must be carried out for each of theouter chord 105, theweb 106 and theinner chord 107. This invites an elongated lead time. - The present invention has been made in view of the foregoing points, and therefore its object is to provide a frame light in weight and small in the number of process steps and a method for fabricating the same.
- In a first aspect of the invention, a frame comprises: an outer frame member of T-shaped section having an extension extending inwardly; and an inner frame member having a flat portion abutting against the extension of the outer frame member, wherein the outer frame member and the inner frame member are friction stir welded together with the edge of the extension of the outer frame member abutted against the edge of the flat portion of the inner frame member.
- In a second aspect of the invention, the frame according to the first aspect is characterized in that the inner frame member is formed of two or more frame members friction stir welded together with one abutted against another.
- In a third aspect of the invention, a method for fabricating a frame comprises the steps of: preparing an outer frame member of T-shaped section having an extension extending inwardly; preparing an inner frame member having a flat portion abutting against the extension of the outer frame member; and friction stir welding the outer frame member and the inner frame member with the edge of the extension of the outer frame member abutted against the edge of the flat portion of the inner frame member.
- In a fourth aspect of the invention, the method according to the third aspect is characterized in that the step of preparing an inner frame member comprises the step of friction stir welding two or more frame members with one abutted against another.
- In a fifth aspect of the invention, the method according to the third or fourth aspect is characterized by further comprising, after friction stir welding the outer frame member and the inner frame member, the step of subjecting the outer and inner frame members together to surface treatment or finish coating.
- According to the first and third aspects of the invention, the inner and outer frame members are joined together by friction stir welding, and therefore no fasteners are needed for the joining. As a result, the frame can be reduced in weight by the weight corresponding to fasteners that would conventionally be required. Furthermore, since the inner and outer frame members are joined together with one abutted against the other, no overlapping portion between both the members is needed. Therefore, the frame of the invention can have a smaller weight than the conventional frame by the weight corresponding to the overlapping portions.
- According to the second and fourth aspects of the invention, the inner frame member is formed by butting two or more frame members together. Therefore, the frame diametral dimension (or lateral width) can be increased. Since the frame members constituting the inner frame member are friction stir welded together with one abutted against another, there is no need for fasteners for the joining of them and also no need for their overlapping portions. Therefore, the inner frame member can be reduced in weight.
- According to the fifth aspect of the invention, the inner and outer frame members need not be subjected individually to surface treatment or finish coating. Therefore, the number of process steps and the lead time can be reduced.
-
FIG. 1 is a perspective view of a frame. -
FIG. 2 is a flow chart of a method for fabricating a frame. -
FIG. 3A is a perspective view showing an extrusion for an outer chord. -
FIG. 3B is a perspective view showing an outer chord. -
FIG. 4A is a perspective view showing an extrusion for an inner chord. -
FIG. 4B is a perspective view showing an inner chord. -
FIG. 5 is a perspective view of another frame. -
FIG. 6 is a perspective view of still another frame. -
FIG. 7 is a flow chart of another method for fabricating a frame. -
FIG. 8 is a perspective view of a body. -
FIG. 9A is a perspective view of a conventional frame. -
FIG. 9B is a cross-sectional view of the conventional frame. -
FIG. 10 is a flow chart showing a method for fabricating a conventional frame. - Hereinafter, description will be made of embodiments of the present invention with reference to the drawings.
- A
frame 1 according to this embodiment is used as a frame in an airplane body of monocoque or semi-monocoque construction. The entire structure of the monocoque or semi-monocoque body is well known, and therefore explanation thereof is not given herein (seeFIG. 8 ). -
FIG. 1 shows the structure of theframe 1. Theframe 1 is formed of anouter chord 2 of T-shaped section having anextension 4 extending inwardly, and aninner chord 3 of L-shaped section having aflat portion 5. In this embodiment, theouter chord 2 and theinner chord 3 are made from aluminum. Theouter chord 2 and theinner chord 3 are formed to have an elongate shape, and are curved along the inner periphery of the airplane body. In this embodiment, the inner edge of theouter chord 2 and the outer edge of theinner chord 3 have the same curvature. Theouter chord 2 and theinner chord 3 are friction stir welded together with the edge of theextension 4 abutted against the edge of theflat portion 5. Theextension 4 and theflat portion 5 are welded continuously on their seam, whereby theframe 1 are formed with a joint 6 extending along its curvature. - In the case of a semi-monocoque body, the frames intersect with stringers and an outer panel is provided on the body surface sides of these members. The frame and the stringer are equal in that they act as reinforcing members. Both the members, however, are different in that the stringer is a member extending along the longitudinal direction of the body, while the frame is a member orthogonal to the longitudinal direction of the body and extending along the inner periphery of the body. By reason of this difference, the frame is actually designed and fabricated from a different view point from the fabrication of the stringer.
- Next, a fabrication method for the
frame 1 will be described with reference to the flow chart ofFIG. 2 . First, in step S1, a straight extrusion 10 (seeFIG. 3A ) of T-shaped section is fabricated by extruding or drawing. Then, in step S2, theextrusion 10 is bent by stretch forming. In this manner, an outer chord 2 (seeFIG. 3B ) is prepared from theextrusion 10. Thereafter, heat treatment is conducted on the preparedouter chord 2 as necessary to complete the outer chord 2 (see step S3). It is needless to say that instead of fabricating anextrusion 10, a standard extrusion can be purchased and anouter chord 2 can be prepared from the purchased extrusion. - For the preparation of an
inner chord 3, a straight extrusion 11 (seeFIG. 4A ) of L-shaped section is first fabricated by extruding or drawing in step S4. Then, in step S5, theextrusion 11 is bent by stretch forming. In this manner, an inner chord 3 (seeFIG. 4B ) is prepared from theextrusion 11. Thereafter, heat treatment is conducted on the preparedinner chord 3 as necessary to complete the inner chord 3 (see step S6). Also for theinner chord 3, it is needless to say that instead of fabricating anextrusion 11, a standard extrusion can be purchased and aninner chord 3 can be prepared from the purchased extrusion. - The fabrication process for an
outer chord 2 in steps S1 to S3 and the fabrication process for aninner chord 3 in steps S4 to S6 are individually conducted. Therefore, both the fabrication processes may be carried out concurrently or one after the other. - Next, in step S7, the completed
outer chord 2 andinner chord 3 are friction stir welded together with theextension 4 of theouter chord 4 abutted against theflat portion 5 of theinner chord 3. In this embodiment, theouter chord 2 and theinner chord 3 are welded continuously to draw a curve on their seam. However, there is no particular limit to welding points of the friction stir welding. For example, both the chords may be welded at discrete points on the seam, or may be welded discontinuously to draw a dotted curve. - After the outer and
inner chords inner chords frame 1. Thereafter, the outer andinner chords - For the purpose of weight reduction of the
frame 1, as shown inFIG. 5 , theflange 9 may be formed with cutaways (flange trims) 7 or holes (not shown). Alternatively or additionally, the flat portion (web) 5 may be formed withholes 8. In these cases, the formation of cutaways or holes is carried out after the friction stir welding in step S7. - As can be seen from the discussion above, the
frame 1 according to this embodiment can be reduced in weight because of the absence of fasteners. Furthermore, the outer andinner chords frame 1 of this embodiment can have a smaller weight than the conventional frame by the weight corresponding to the overlapping portions. - The joining of the outer and
inner chords members - Each of surface treatment and finish coating can be conducted on the outer and
inner chords inner chords - Next, as a modification, description will be made of a
frame 15 formed of anouter chord 2, aninner chord 3 and aweb 12 like a flat plate with reference toFIG. 6 . Thisframe 15 includes theweb 12 between theouter chord 2 and theinner chord 3, so that the frame diametral dimension (or the flame lateral width) is increased. Theouter chord 2, theinner chord 3 and theweb 12 are all made of aluminum. In this modification, theouter chord 2 constitutes an outer frame member, while theinner chord 3 and theweb 12 constitute an inner frame member. -
FIG. 7 shows a flow chart of a method for fabricating aframe 15. In this method, the outer andinner chords web 12 is formed by cutting a flat plate (sheet metal) of aluminum into a predetermined shape. Thereafter, theouter chord 2 and theweb 12 are friction stir welded together with theextension 4 of theouter chord 2 abutted against one edge of theweb 12, and theweb 12 and theinner chord 3 are also friction stir welded together with the other edge of theweb 12 abutted against one edge of the inner chord 3 (step S7). Then, the weldedouter chord 2,web 12 andinner chord 3 are together subjected to surface treatment (step S8) and then finish coating (step S9), thereby implementing aframe 15. - Therefore, the foregoing various effects can also be achieved according to the
frame 15 and its fabrication method. - The number of
webs 12 provided is not restricted to one. If necessary, two or more webs can be abutted and friction stir welded together to further increase the frame diametral dimension. - The material for the
frames frames - The
frames - The
frames frames
Claims (6)
1. A frame comprising:
an outer frame member of T-shaped section having an extension extending inwardly; and
an inner frame member having a flat portion abutting against the extension of the outer frame member,
wherein the outer frame member and the inner frame member are friction stir welded together with the edge of the extension of the outer frame member abutted against the edge of the flat portion of the inner frame member.
2. The frame of claim 1 , wherein the inner frame member is formed of two or more frame members friction stir welded together with one abutted against another.
3. A method for fabricating a frame, comprising the steps of:
preparing an outer frame member of T-shaped section having an extension extending inwardly;
preparing an inner frame member having a flat portion abutting against the extension of the outer frame member; and
friction stir welding the outer frame member and the inner frame member with the edge of the extension of the outer frame member abutted against the edge of the flat portion of the inner frame member.
4. The method for fabricating a frame of claim 3 , wherein the step of preparing an inner frame member comprises the step of friction stir welding two or more frame members with one abutted against another.
5. The method for fabricating a frame of claim 3 , further comprising, after friction stir welding the outer frame member and the inner frame member, the step of subjecting the outer and inner frame members together to surface treatment or finish coating.
6. The method for fabricating a frame of claim 4 , further comprising, after friction stir welding the outer frame member and the inner frame member, the step of subjecting the outer and inner frame members together to surface treatment or finish coating.
Priority Applications (1)
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US10/807,136 US20050210820A1 (en) | 2004-03-24 | 2004-03-24 | Frame and method for fabricating the same |
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US10/807,136 US20050210820A1 (en) | 2004-03-24 | 2004-03-24 | Frame and method for fabricating the same |
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US20050210820A1 true US20050210820A1 (en) | 2005-09-29 |
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US10/807,136 Abandoned US20050210820A1 (en) | 2004-03-24 | 2004-03-24 | Frame and method for fabricating the same |
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US20090311549A1 (en) * | 2008-06-16 | 2009-12-17 | Fernando Ferreira Fernandez | Friction stir welding (fsw) methods and systems and friction stir welded components made thereby |
US20100148005A1 (en) * | 2004-12-06 | 2010-06-17 | Saab Ab | Curved beam of fiber composite material |
US8397974B2 (en) | 2005-09-26 | 2013-03-19 | Aeroprobe Corporation | Self-reacting friction stir welding tool with the ability to add filler material |
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US8632850B2 (en) | 2005-09-26 | 2014-01-21 | Schultz-Creehan Holdings, Inc. | Friction fabrication tools |
US8636194B2 (en) | 2005-09-26 | 2014-01-28 | Schultz-Creehan Holdings, Inc. | Friction stir fabrication |
US8875976B2 (en) | 2005-09-26 | 2014-11-04 | Aeroprobe Corporation | System for continuous feeding of filler material for friction stir welding, processing and fabrication |
US9266191B2 (en) | 2013-12-18 | 2016-02-23 | Aeroprobe Corporation | Fabrication of monolithic stiffening ribs on metallic sheets |
US9511445B2 (en) | 2014-12-17 | 2016-12-06 | Aeroprobe Corporation | Solid state joining using additive friction stir processing |
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US10745914B1 (en) * | 2019-06-06 | 2020-08-18 | Fox Hardwood Lumber Company, LLC | Curved brace |
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