Structural analysis of a friction stir-welded small trailer

Abstract

This paper introduces the analysis of a trailer structure made of 6063-T5 aluminum alloy using the Friction Stir-Welding process. The base material and the welded joint were characterized by tension tests. The loads for the structural analysis were obtained from field tests where stresses were measured on critical points at a 2.73 m long 0.95 m width trailer while it was driven on an unpaved road. The stresses on the whole trailer were found by using a finite element model, where the joint with the maximum stresses was identified. This joint was constructed with a tubular structural element using Friction Stir Welding and was evaluated by bending tests. Using the impact factor obtained from the field test, fatigue analysis was performed on the welded joint. It was found that the strength of the joint was sufficient to carry the loads on the trailer.