Large friction stir welded metallic components

Abstract

A method is provided for forming a large metallic component using a friction stir welded blank. A first and second metallic plate are positioned in an abutting arrangement with corresponding faying surfaces. A backing plate is attached across the abutment. The plates are friction stir welded along the faying surfaces, the friction stir weld including a weld root that terminates in the backing plate. After welding, the backing plate is removed, including the weld root, to create a welded blank. The blank is then formed into a desired component shape, heat treated and aged to produce the final large metallic component. The resulting friction stir weld has a stable microstructure with minimal or no abnormal grain growth during high-temperature forming, heat treatment, or aging.

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