Refill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

Because of its light weight, high strength, designable, composite materials are more and more widely used in the field of aerospace, especially in the field of general aviation. In this paper, the structural design and analysis of the composite wing (include wing beam, rib, skin, leading edge and trailing edge) of a four-seater electric aircraft were carried out. The finite element numerical analysis model of the composite wing was established, and the deformation and strain distribution of the composite wing under the limited load required by airworthiness regulations were calculated. Finally, the static test of the whole composite wing was carried out to verify the accuracy of the finite element results. The finite element analysis and testing results showed that the structural design of the composite wing of the electric aircraft meets the structural strength requirements specified in the airworthiness standard (part 23 of China civil aviation regulations: air-worthiness requirements for normal, practical, special effects and commuting aircraft: CCAR 23-R3)

Composite sandwich structures are widely used in the aerospace field due to their advantages of high strength, lightweight, and fatigue resistance. However, these structures are prone to damage with very-low-energy impacts. In order to improve the impact resistance of aircraft skin structure, a low-velocity impact resistance of sandwich structure specimens was tested by means of drop hammer impact, and the impact damage area was scanned by ultrasonic C-scan, and obtains the impact damage of specimens with different impact energies and different ply sequences. Combined with the Hashin failure criterion, the finite element equivalent model of composite sandwich structure under low-velocity impact was established. The errors between the simulation results and the C-scan results of the test piece were less than 10%, in which the experimental measurements and numerical predictions were in close agreement. Finally, the finite element equivalent model was applied to optimize the application of model sandwich, which was used for fuselage skin of a certain electric aircraft. The total thickness of the laminate structure remains unchanged before and after optimization, but the impact resistance was significantly enhanced. The ±45° lay-up was beneficial for the structure to absorb the impact energy.