Joining Dissimilar Mg/Al Alloys by Solid-State Friction Spot Welding

JOM ◽  
2019 ◽  
Vol 71 (5) ◽  
pp. 1760-1767 ◽  
Author(s):  
Peng Chai ◽  
Kang Yang ◽  
Shude Ji ◽  
XinXin Ai ◽  
Zan Lv ◽  
...  
Keyword(s):  
Solid State ◽  
Spot Welding ◽  
Al Alloys ◽  
Friction Spot Welding

scholarly journals Friction Spot Welding of Similar AA5754 to AA5754 Aluminum Alloys and Dissimilar AA5754 Aluminum to AZ31 Magnesium Alloys

2015 ◽  
Vol 1112 ◽  
pp. 485-488 ◽  
Author(s):  
U.F.H. Suhuddin ◽  
Debora Piccolo ◽  
Vanessa Fischer ◽  
Jorge F. dos Santos
Keyword(s):  
Solid State ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
Spot Welding ◽  
Flat Surface ◽  
Welding Process ◽  
Al Alloys ◽  
Mg Alloys ◽  
Material Loss ◽  
Friction Spot Welding

Friction spot welding is a solid-state spot welding process developed and patented by Helmholtz-Zentrum Geesthacht, Germany. A non-consumable rotating tool consisting of two rotating parts, a pin and a sleeve, and one stationary clamping ring is used to join two or more similar/dissimilar sheets of materials in lap configuration. The result is a spot welded lap connection with minimal material loss and a flat surface without keyhole. The present work presents a summary of results from studies in similar AA5754 to AA5754 Al alloys and dissimilar AA5754 Al to AZ31 Mg alloys.

scholarly journals Novel Approaches to Friction Spot Welding Thin Aluminium Automotive Sheet

2010 ◽  
Vol 638-642 ◽  
pp. 1237-1242 ◽  
Author(s):  
Philip B. Prangnell ◽  
Dimitrios Bakavos
Keyword(s):  
Solid State ◽  
High Power ◽  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
Weld Formation ◽  
Friction Stir ◽  
Friction Spot Welding ◽  
Automotive Sheet ◽  
Novel Approaches ◽  
The Relationship

Conventional welding methods, like resistance spot welding, are inefficient and difficult to apply to light alloys. Two alternative new solid state friction joining techniques, which have not yet been fully optimized, are high power Ultrasonic Spot and Friction Stir Spot Welding (USW & FSSW). Here we have compared the performance for these two processes for producing ‘keyhole-less’ welds in thin aluminium automotive closure panels. For friction stir spot welding this was achieved through using a novel ‘pinless’ tool to create a joint without a retained keyhole and reduce the weld cycle time. The properties of the welds that can be produced by each technique are compared, together with the stages of weld formation, and the relationship between welding conditions and joint performance.

scholarly journals Eutectic structures in friction spot welding joint of aluminum alloy to copper

2014 ◽  
Vol 104 (19) ◽  
pp. 191901 ◽  
Author(s):  
Junjun Shen ◽  
Uceu F. H. Suhuddin ◽  
Maria E. B. Cardillo ◽  
Jorge F. dos Santos
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Welding Joint ◽  
Friction Spot Welding

Application of Laser Remote Welding to an Aluminum Automotive Part

2010 ◽  
Vol 654-656 ◽  
pp. 966-969
Author(s):  
Cheol Hee Kim ◽  
Won Ho Choi ◽  
Ki Young Park
Keyword(s):  
Laser Welding ◽  
Automotive Industry ◽  
Spot Welding ◽  
Thin Disk ◽  
Al Alloys ◽  
Thermal Distortion ◽  
Focal Distance ◽  
High Brightness ◽  
Automotive Part ◽  
Remote Welding

Aluminum alloys are extensively used in the automotive industry in response to increasing requirements for weight reduction in car body architecture. Laser welding of Al alloys has many advantages such as low heat input, narrow heat affected zone, minimal thermal distortion and flexibility. Recently, the development of high brightness lasers - thin disk lasers and fiber lasers enable long focal distance welding so that laser remote welding with scanning mirrors can be used in laser welding of Al alloys. In this study, laser remote welding was implemented to a heat shield part of an automobile by utilizing a 4kW disk laser and a 2-axis scanner. By replacing conventional resistance spot welding, the weld flange length could be reduced from 15mm to 8mm and a cycle time for each welding point could also be reduced from 3.5s to 0.6s.

Effect of Tool Shape on Temperature Field in Friction Stir Spot Welding

2013 ◽  
Vol 58 (2) ◽  
pp. 595-599 ◽  
Author(s):  
P. Lacki ◽  
Z. Kucharczyk ◽  
R.E. Śliwa ◽  
T. Gałaczyński
Keyword(s):  
Temperature Field ◽  
Solid State ◽  
Spot Welding ◽  
Plastic Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Frictional Heat ◽  
Maximum Temperature ◽  
Tool Geometry ◽  
Friction Stir

Friction stir welding (FSW) is one of the youngest methods of metal welding. Metals and its alloys are joined in a solid state at temperature lower than melting points of the joined materials. The method is constantly developed and friction stir spot welding (FSSW) is one of its varieties. In the friction stir spot welding process a specially designed tool is brought into rotation and plunged, straight down, in the joined materials. Heat is generated as a result of friction between the tool and materials, and plastic deformation of the joined materials. Softening (plastic zone) of the joined materials occurs. Simultaneously the materials are stirred. After removal of the tool, cooling down the stirred materials create a solid state joint. Numerical simulation of the process was carried out with the ADINA System based on the finite element method (FEM). The problem was considered as an axisymmetric one. A thermal and plastic material model was assumed for Al 6061-T6. Frictional heat was generated on the contact surfaces between the tool and the joined elements. The model of Coulomb friction, in which the friction coefficient depends on the temperature, was used. An influence of the tool geometry on heat generation in the welded materials was analysed. The calculations were carried out for different radiuses of the tool stem and for different angles of the abutment. Temperature distributions in the welded materials as a function of the process duration assuming a constant value of rotational tool speed and the speed of tool plunge were determined. Additionally, the effect of the stem radius and its height on the maximum temperature was analysed. The influence of tool geometry parameters on the temperature field and the temperature gradient in the welded materials was shown. It is important regarding the final result of FSSW.

Formation of Intermetallic Compounds in Dissimilar Friction Spot Weld of Al to Mg Alloys

2013 ◽  
Vol 765 ◽  
pp. 731-735 ◽  
Author(s):  
Uceu Suhuddin ◽  
Vanessa Fischer ◽  
Jorge dos Santos
Keyword(s):  
Plastic Deformation ◽  
Spot Welding ◽  
Dwell Time ◽  
Welding Process ◽  
Eutectic Structure ◽  
Mixed Solution ◽  
Microstructure Formation ◽  
Friction Spot Welding ◽  
Welding Cycle ◽  
Insight Into

In the present study, friction spot welding has been used for joining dissimilar AA5754 aluminum to AZ31 magnesium alloys. To get more insight into the microstructure, stop-action experimentation was employed. The welding cycle was forced to stop during the dwell time, and subsequently, the weld was quenched by pouring a mixed solution of ice and water to freeze the microstructure. Formation of the liquid phase leading to a formation of brittle intermetallic compound has been studied. Microstructural analyses reveal that formation of intercalated layers and a high density of grain boundaries induced by plastic deformation enhance the formation of eutectic structure during the welding process.

Experimental Investigation on Solid State Resistance Spot Welding

2017 ◽  
Author(s):  
Zhijun Wu ◽  
Guanlin Zhang ◽  
Bingxu Wang ◽  
Kelvin Shih
Keyword(s):  
Solid State ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Mechanical Performance ◽  
Thin Sheet ◽  
Welding Current ◽  
Sheet Metals ◽  
Resistance Spot ◽  
Nugget Formation ◽  
State Resistance

Resistance Spot Welding (RSW) is one of the most common and dominant technologies utilized in the automotive industry to join the thin sheet metals together, and expulsion is a common phenomenon during the operation. How to ensure the high quality nugget formation and joining performance is essential to ensure the quality and integrity of structures. In this study, solid state resistance spot welding is introduced in order to prevent expulsion. The effect of welding current and welding time on the mechanical performance of the solid state RSW in terms of nugget size, tensile performance and nugget formation will be investigated experimentally by using steel sheet metals. Microstructure and micro-hardness of the nugget cross-section will be evaluated as well.

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