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<p>Aluminium alloys’ tubular structures are attractive for lightweight body-in-white (BIW) design in electric vehicles without compromising crashworthiness; however, manufacturability of these tubes through extrusion process is limited by tube size, dedicated dies and forming load. The present work proposes an alternative fabrication route by longitudinally welding pre-rolled open cylindrical tubes of AA&#xa0;5083 employing friction stir welding (FSW). A customized welding fixture and concave shoulder tool were developed to securely position the tubes and ensure proper tool contact. Micro CT-scan and macroscopic analysis revealed negligible porosity and thickness inhomogeneity in the weld zone (WZ), respectively. The structural performance of fabricated tubes was assessed by conducting end forming and axial crushing tests. The WZ was able to sustain significant circumferential stretching before fracture during expansion despite localized thinning, while no sign of fracture was observed during crushing. Specific energy absorption of the tubes was comparable with the conventionally extruded tubes reported in the literature. These findings demonstrated that FSWed AA&#xa0;5083 tubes offer a viable alternative to extrusion for lightweight BIW structures.</p>

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Forming and Crushing Performance of AA 5083 Cylindrical Tubes Fabricated using Friction Stir Welding Process

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Debolina Sen,
  • Bhupesh Singh Katiyar

摘要

Aluminium alloys’ tubular structures are attractive for lightweight body-in-white (BIW) design in electric vehicles without compromising crashworthiness; however, manufacturability of these tubes through extrusion process is limited by tube size, dedicated dies and forming load. The present work proposes an alternative fabrication route by longitudinally welding pre-rolled open cylindrical tubes of AA 5083 employing friction stir welding (FSW). A customized welding fixture and concave shoulder tool were developed to securely position the tubes and ensure proper tool contact. Micro CT-scan and macroscopic analysis revealed negligible porosity and thickness inhomogeneity in the weld zone (WZ), respectively. The structural performance of fabricated tubes was assessed by conducting end forming and axial crushing tests. The WZ was able to sustain significant circumferential stretching before fracture during expansion despite localized thinning, while no sign of fracture was observed during crushing. Specific energy absorption of the tubes was comparable with the conventionally extruded tubes reported in the literature. These findings demonstrated that FSWed AA 5083 tubes offer a viable alternative to extrusion for lightweight BIW structures.