Analysis of Static Strength and Failure Mode of FSSW Joint in Aluminum Alloy

2014 ◽  
Author(s):  
Francesco Vivio ◽  
Vincenzo Vullo ◽  
Pierluigi Fanelli
Keyword(s):  
Aluminum Alloy ◽  
Failure Mode ◽  
Mechanical Characteristics ◽  
Experimental Tests ◽  
Static Strength ◽  
Structural Behavior ◽  
Fe Model ◽  
Lap Joint ◽  
Actual Distribution ◽  
Friction Stir

In this paper an analysis of Friction Stir Spot Welds (FSSW), applied to lap joint aluminum alloy is presented. The analyses regards the structural behavior of FSSW joints in order to assess the failure mode and its dependence on mechanical properties distribution of the sheets material and, consequently, on process parameters. FSSW joint is analyzed by means of a complex 3D FE model, which allows to evaluate, in a parametric manner, the multifaceted internal geometry of the joint and the actual distribution of material mechanical characteristics after welding. Experimental tests allowed to verify the results and to calibrate the material characteristics in the FE model.

Interfacial Reaction during Dissimilar Friction Stir Lap Welding of Aluminum Alloy to Stainless Steel

2014 ◽  
Vol 794-796 ◽  
pp. 389-394
Author(s):  
Tomo Ogura ◽  
Taichi Nishida ◽  
Makoto Takahashi ◽  
Hidehito Nishida ◽  
Mitsuo Fujimoto ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloy ◽  
Intermetallic Compounds ◽  
Lap Joint ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Transmission Electron ◽  
Lap Welding ◽  
Mixed Layers ◽  
Joining Process

A friction stir welded A3003 aluminum alloy /SUS304 stainless steel dissimilar lap joint was successfully produced. A sound joint that fractured at the base metal was obtained in the center region of the joint through the reaction layer of aluminum-rich intermetallic compounds with nanoorder thickness. The microstructural changes at the interface of the joint was examined by studying the hole left by the extracted welding tool produced at the end of the friction stir welding (FSW) bead using transmission electron microscopy (TEM). Mixed layers consisted of ultra-fined intermetallic compounds and stainless steel were observed. The stirred aluminum alloy flows onto the mixed layer after the tool transit and the joining was achieved. Based on the TEM observations, the joining process of the lap joint was also discussed.

scholarly journals Effects of probe tip position on microstructure and bonding strength of friction stir welded aluminum alloy/steel lap joint

2007 ◽  
Vol 57 (11) ◽  
pp. 529-535 ◽  
Author(s):  
Shinji KUMAI ◽  
Hiromasa SATO ◽  
Kenta SUZUKI ◽  
Takeshi OOKAWA ◽  
Kwang-jin LEE ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Alloy Steel ◽  
Bonding Strength ◽  
Lap Joint ◽  
Friction Stir ◽  
Tip Position

scholarly journals Lap Joint of A5083 Aluminum Alloy and SS400 Steel by Friction Stir Welding

2005 ◽  
Vol 46 (4) ◽  
pp. 835-841 ◽  
Author(s):  
Kittipong Kimapong ◽  
Takehiko Watanabe
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Lap Joint ◽  
Friction Stir

Joint Formation and Mechanical Performance of Friction Self-Piercing Riveted Aluminum Alloy AA7075-T6 Joints

2019 ◽  
Author(s):  
YunWu Ma ◽  
YongBing Li ◽  
ZhongQin Lin
Keyword(s):  
Aluminum Alloy ◽  
Failure Mode ◽  
Feed Rate ◽  
High Speed ◽  
Shear Failure ◽  
Shear Fracture ◽  
Peak Load ◽  
Spindle Speed ◽  
Friction Stir ◽  
Lap Shear

Abstract AA7xxx series aluminum alloys have great potentials in mass saving of vehicle bodies due to pretty high specific strength. However, the use of these high strength materials poses significant challenges to traditional self-piercing riveting (SPR) process. To address this issue, friction self-piercing riveting (F-SPR) was applied to join aluminum alloy AA7075-T6 sheets. F-SPR is realized by feeding a high speed rotating steel rivet to aluminum alloy sheets to form a dissimilar material joint. The effects of spindle speed and rivet feed rate on F-SPR joint cross-section geometry evolution, riveting force and energy input were investigated systematically. It was found that the rivet shank deformation, especially the buckling of the shank tip before penetrating through the top sheet has significant influence on geometry and lap-shear failure mode of the final joint. A medium rivet feed rate combined with a high spindle speed was prone to produce a defect free joint with sound mechanical interlocking. F-SPR joints with the failure mode of rivet shear fracture was observed to have superior lap-shear peak load and energy absorption over the joints with mechanical interlock failure. The optimized F-SPR joint in this study exhibited 67.6% and 13.9% greater lap-shear peak load compared to, respectively, SPR and refill friction stir spot welding joints of the same sheets. This research provides a valuable reference for further understanding the F-SPR process.

Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint

2015 ◽  
Vol 24 (11) ◽  
pp. 4192-4199 ◽  
Author(s):  
H. Das ◽  
A. Kumar ◽  
K. V. Rajkumar ◽  
T. Saravanan ◽  
T. Jayakumar ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Nondestructive Evaluation ◽  
Steel Sheet ◽  
Coated Steel ◽  
Lap Joint ◽  
Friction Stir ◽  
Coated Steel Sheet
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