Numerical simulation of creep forming processes of large-scale and friction stir welded AlMgSc sheets of aeronautical applications

The creep forming process of large-scale and friction stir welded aluminum sheets show a high potential for aeronautical applications, e.g. to replace the conventionally used cold stretch forming technology to produce thin-walled and doubled curved fuselage structures. Especially the novel aluminum alloy AlMgSc (AA5028) provides ideal conditions for the creep forming process due to its thermal stability (i.e. high recrystallization temperature). Furthermore, AlMgSc has excellent characteristics for the use in airframe structures and shows a good weldability. Hence, numerical and experimental investigations are conducted on the forming behavior of welded and spherically curved AlMgSc panels. The numerical analyses are performed as thermomechanical coupled FE simulations in order to determine the forming behavior and to optimize the forming results as function of geometrical dimensions and process parameters. The paper will show the numerical simulation using the finite element analysis and its results in comparison to the experimental verfication.