Joining process and strength in PVC friction stir spot welding with fabricating composite material at welding area

Abstract Friction stir spot welding is a solid-state joining process that has attracted significant attention particularly in the field of joining of lightweight, low melting alloys. These materials include alloys of Aluminium and Magnesium amongst many others which are of great importance to the aerospace and the automobile industries. The friction stir spot welding is a complex thermo-mechanical multiphysics phenomenon and is currently a field of intense research. The motivation of the current study is to understand this complex behaviour of the joining process by simulating it in the ABAQUS CAE environment. In the friction stir spot joining technique, the plunge stage is identified as the critical stage of operation as it involves a highly transient and dynamic zone for material and temperature flows. The plunge stage was studied in detail using the finite element based model. The plasticity of the material was simulated by the Johnson-Cook material model while the frictional heat generation was captured by applying a penalty-based frictional contact between the rotating tool and the workpiece contact surfaces. Considering the reasonable assumptions made, the results obtained by the numerical simulation model were found to agree with the past experimental and numerically modelled studies.

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Friction Self-Piercing Riveting (F-SPR) of AA6061-T6 to AZ31B

Volume 2B: Advanced Manufacturing ◽

10.1115/imece2013-64212 ◽

2013 ◽

Author(s):

YongBing Li ◽

ZeYu Wei ◽

YaTing Li ◽

ZhaoZhao Wang ◽

Xiaobo Zhu

Keyword(s):

Magnesium Alloys ◽

Spot Welding ◽

High Speed ◽

Dissimilar Materials ◽

Friction Stir Spot Welding ◽

Friction Stir ◽

Riveting Process ◽

Solid State Joining ◽

Joining Process ◽

Vehicle Bodies

Implementation of lightweight low-ductility materials such as aluminum alloys, magnesium alloys and composite materials has become urgently needed for automotive manufacturers to improve the competitiveness of their products. However, the hybrid use of these materials poses big challenges to joining processes. Self-piercing riveting (SPR) is currently the most popular technique for joining dissimilar materials and has been widely used in joining all-aluminum and multi-material vehicle bodies. However, in riveting magnesium alloys, cracks always occur for its low ductility. In this paper, a hybrid joining process named friction self-piercing riveting (F-SPR), which combines mechanical joining mechanism of SPR with solid-state joining mechanism of friction stir spot welding (FSSW) by making rivet rotating at high speed in riveting process, was proposed aiming at joining the low ductility materials. 1-mm-thick AA6061-T6 and 2-mm-thick AZ31B were used to validate the effectiveness of the F-SPR process. The results showed that the F-SPR process could significantly improve the rivetability of magnesium alloys, and greatly increase the joint strength, comparing with traditional SPR process.

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Numerical Simulation of Friction Stir Spot Welding of Aluminium-6061 and Magnesium AZ-31B

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1048.241 ◽

2022 ◽

Vol 1048 ◽

pp. 241-253

Author(s):

Arindom Baruah ◽

Jayaprakash Murugesan ◽

Hemant Borkar

Keyword(s):

Numerical Simulation ◽

Spot Welding ◽

High Efficiency ◽

Welding Process ◽

Friction Stir Spot Welding ◽

Tool Geometry ◽

Friction Stir ◽

Finite Element Software ◽

Point Light ◽

Joining Process

Friction stir spot welding process is a solid state joining process which has attracted great attention due to its ability to join low melting point light weight alloys such as aluminium and magnesium with high efficiency. In order to understand the complex thermo-mechanical joining process involved with friction stir spot welding, a numerical simulation study was done using ABAQUS finite element software. The simulation primarily aims to interpret the effect of a set of process parameters and tool geometry on the workpiece plates. Johnson-Cook damage criteria model was used to obtain the stress and strain distribution on the workpiece consisting of aluminium 6061 and magnesium AZ-31B placed in a lap configuration. Temperature distribution of the workpiece was obtained by simulating a penalty based frictional contact between the tool and the plate. The thermal results showed that the maximum temperatures attained were significantly lower than the melting points of the base materials indicating that the material mixing and joining occurred as a result of superplastic deformation process instead of melting. Change in material flow behaviour was also observed by the model as pin and shoulder geometries changed.

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