scholarly journals Spot Welding of 6061 Aluminum Alloy by Friction Stir Spot Welding Process

2017 ◽  
Vol 7 (3) ◽  
pp. 1629-1632 ◽  
Author(s):  
M. A. Tashkandi ◽  
J. A. Al-jarrah ◽  
M. Ibrahim
Keyword(s):  
Welded Joints ◽  
Spot Welding ◽  
Shear Fracture ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameters ◽  
Friction Stir ◽  
Pull Out ◽  
Lap Shear

This study was focused on the effect of welding parameters on the lap-shear fracture load of the welded joints prepared by friction stir spot welding. Four different weld parameters were analyzed: rotational speed, dwell time, pin length and shoulder size of the welding tool. It was found that the lap-shear fracture load increases with an increase of the welding parameters to a limited value and decreases with further increase. The strong welded joints failed under nugget-pull out fracture.

Taguchi Optimization of Process Parameters in Friction Stir Spot Welding of AA5754 and AA2024 Alloys

2014 ◽  
Vol 1016 ◽  
pp. 161-166 ◽  
Author(s):  
Y. Bozkurt ◽  
Mustafa Kemal Bilici
Keyword(s):  
Spot Welding ◽  
Shear Fracture ◽  
Signal To Noise Ratio ◽  
Statistical Design ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameters ◽  
Taguchi Optimization ◽  
Friction Stir ◽  
Lap Shear

The feasibility of friction stir spot welding was studied on AA5754-H22 and AA2024-T3 aluminum alloys which have widespread applications in aircraft and automotive industries. The quality of the joint was evaluated by examining the characteristics of the joint as a result of lap-shear fracture load. Taguchi approach of the parameter design was used as a statistical design of experiment technique to set the optimal welding parameters. The experiments were arranged by using Taguchi’s L9 orthogonal array. The signal-to-noise ratio and the analysis of variance were utilized to obtain the influence of the friction stir spot welding parameters on the lap-shear fracture load. Finally, the results were confirmed by further experiments.

Influence of Heating Friction Stir Spot Welding Process Parameters on Steel Aluminum Forming Quality

2018 ◽  
Vol 917 ◽  
pp. 246-251
Author(s):  
Kai Xu ◽  
Shu Quan Zhang
Keyword(s):  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Joint Line ◽  
Welding Parameters ◽  
Forming Quality ◽  
Rotating Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Pressure

A lap welding experiment of DP590 steel and 6061 aluminum plate is carried out by using Heating Friction Stir Spot Welding (HFSSW) to study the influence of welding parameters on the forming quality. The results show that a lap joint with better forming can be obtained for the dissimilar metal of steel and aluminum. Under the condition that the rotating speed of the stirring tool is 1000r/min, the penetration depth, 0.2mm, the dwell time, 90s, the welding pressure, 0.2Mp, and the flow rate of cooling air, 20L/min, the forming quality of the surface of the joint line is good & bright, and the exit hole is also smaller. The mechanism of heat production is revealed in the following: the main heat is produced by the friction between the stirring tool shoulder and the welded part & between the probe and the welded part as well as by the latent heat resulted from the plastic deformation of the material in joint line during welding.

Electrically Assisted Friction Stir Spot Welding of Aluminum Alloy to Advanced High Strength Steel

2017 ◽  
Author(s):  
Kai Chen ◽  
Xun Liu ◽  
Jun Ni
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Spot Welding ◽  
Aluminum Matrix ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Steel Matrix ◽  
Friction Stir ◽  
Lap Shear ◽  
Electrically Assisted

This paper studies an electrically assisted friction stir spot welding (FSSW) process for joining aluminum alloy 6061-T6 to TRIP 780 steel. The electrical current shows to reduce the axial plunge force and assist the material flow of the aluminum matrix during the welding process. When electrical pulses and direct current (DC) with the same energy input are applied, the results show insignificant differences. Bulk material flow can be observed in the weld cross sections. A more uniform hook is generated at the Fe/Al interface after applying the current. Besides, the diffusion of aluminum atoms into the steel matrix is enhanced. Regarding the weld quality, electrically assisted FSSW improves the joint lap shear strength when compared with regular FSSW process.

scholarly journals Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Metals ◽  
2018 ◽  
Vol 8 (11) ◽  
pp. 922 ◽  
Author(s):  
Xingwen Zhou ◽  
Yuhua Chen ◽  
Shuhan Li ◽  
Yongde Huang ◽  
Kun Hao ◽  
...  
Keyword(s):  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Stir Zone ◽  
Welding Parameters ◽  
Al Alloy ◽  
Ti Alloy ◽  
Friction Stir ◽  
2014 Al Alloy ◽  
Al Coating

Friction stir spot welding (FSSW) of Al to Ti alloys has broad applications in the aerospace and automobile industries, while its narrow joining area limits the improvement of mechanical properties of the joint. In the current study, an Al-coating was prepared on Ti6Al4V alloy by hot-dipping prior to joining, then a Zn interlayer was used during friction stir joining of as-coated Ti alloy to the 2014-Al alloy in a lap configuration to introduce a brazing zone out of the stir zone to increase the joining area. The microstructure of the joint was investigated, and the joint strength was compared with the traditional FSSW joint to confirm the advantages of this new process. Because of the increase of the joining area, the maximum fracture load of such joint is 110% higher than that of the traditional FSSW joint under the same welding parameters. The fracture load of these joints depends on the joining width, including the width of solid-state bonding region in stir zone and brazing region out of stir zone.

scholarly journals Effects of Dwell-Time and Plunge Speed during Micro Friction Stir Spot Welding on Mechanical Properties of Thin Aluminum A1100 Welds

2015 ◽  
Vol 758 ◽  
pp. 29-34 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
M.Dz. Habibullah ◽  
Z. Arvay ◽  
G. Kiswanto ◽  
...  
Keyword(s):  
Spot Welding ◽  
High Speed ◽  
Dwell Time ◽  
Shear Fracture ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameter ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes

Friction Stir Welding is a relatively new technique for joining metal. In some cases on aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and produces less distortion. The purpose of this study is to analyze the effect of high speed tool rotation on micro Friction Stir Spot Welding (μFSSW) to the shear fracture load of the welds. Response Surface Methods was used to analyze μFSSW parameters with the response. The welding material was Aluminum A1100, with thickness of 0.4 mm. The tool was made of HSS material which was shaped by micro grinding process. Tool shoulder diameter is 4 mm, and the pin diameter 1.5 mm with length of pin is 0.6 mm. The spindle speed is fixed at 33,000 rpm. The parameters that varied were the plunge speed (2 mm/min, 3 mm/min, 4 mm/min), and dwell time-1 (0 s, 2 s, 4 s) and variable of dwell time-2 (0 s, 2 s, 4 s). From the results of experiment and analysis, it is shown that the important welding parameter in high speed μFSSW process is dwell time-2.

scholarly journals Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

2019 ◽  
Vol 38 (2019) ◽  
pp. 69-75 ◽  
Author(s):  
Zhenlei Liu ◽  
Kang Yang ◽  
Dejun Yan
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Joint Strength ◽  
Shear Failure ◽  
Failure Load ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear

AbstractRefill 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.

Preliminary Investigation on Friction Spot Welding of AZ31 Magnesium Alloy

2012 ◽  
Vol 706-709 ◽  
pp. 3016-3021 ◽  
Author(s):  
L.C. Campanelli ◽  
U.F.H. Suhuddin ◽  
Jorge Fernandez Dos Santos ◽  
N.G. Alcantara
Keyword(s):  
Magnesium Alloy ◽  
Spot Welding ◽  
Welding Process ◽  
High Energy ◽  
Az31 Magnesium Alloy ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Friction Stir ◽  
Friction Spot Welding ◽  
Lap Shear

Friction spot welding (FSpW) is a recent solid state welding process developed and patented by GKSS Forschungszentrum (now Helmholtz-Zentrum Geesthacht), Germany. A spot-like connection is produced by means of an especially designed non-consumable tool consisting of pin, sleeve and clamping ring that creates a joint between sheets in overlap configuration through frictional heat and plastic deformation. FSpW offers many advantages over conventional spot joining techniques including high energy efficiency, surface quality and environmental compatibility. Comparing with friction stir spot welding, FSpW produces a weld without keyhole on the surface at the end of the joining process. In the present study, the possibility of joining AZ31 magnesium alloy by FSpW technique was evaluated by using different welding parameters (rotational speed, plunge depth and dwell time), aiming to produce high quality connections. Microstructural features were analyzed by light optical microscope and mechanical performance was investigated by microhardness test and lap shear test. Microstructure analysis revealed that defects free welds could be produced. A slight decrease in grain size of the stir zone was observed causing a slight increase in the microhardness of this region. The preliminary lap shear data demonstrated that the weld strength is comparable to other welding process.

scholarly journals A fully coupled thermo-mechanical numerical modelling of the refill friction stir spot welding process in Alclad 7075-T6 aluminium alloy sheets

2020 ◽  
Vol 20 (4) ◽  
Author(s):  
Andrzej Kubit ◽  
Tomasz Trzepiecinski
Keyword(s):  
Numerical Modelling ◽  
Aluminium Alloy ◽  
Spot Welding ◽  
Numerical Models ◽  
Weld Zone ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Fully Coupled

Abstract Refill friction stir spot welding (RFSSW) is a solid state joining technology that has the potential to replace processes such as the open-air fusion bonding technique and rivet technology in aerospace applications. Selection of proper RFSSW parameters is a crucial task which is important to ensure the mechanical strength of the joint. The aim of this paper is to undertake numerical modelling of the RFSSW process to understand the physics of the welding process, which involves large deformations, complex contact conditions and steep temperature gradients. Three-dimensional fully coupled thermo-mechanical models of RFSSW joints between Alclad 7075-T6 aluminium alloy sheets have been built in the finite-element-based program Simufact Forming. The simulation results included the temperature distribution and the stress and strain distributions in the overlap joint. The results of numerical computations have been compared with experimental ones. The numerical model was able to predict the mechanics of material flow during the joining of sheets of Alclad aluminium alloys using RFSSW. The predictions of the temperature gradient in the weld zone were in good agreement with the temperature measured experimentally. The numerical models that have been built are capable of simulating RFSSW to reduce the number of experiments required to set optimal welding parameters.

scholarly journals A Weighting Grade-Based Optimization Method for Determining Refill Friction Stir Spot Welding Process Parameters

2019 ◽  
Vol 28 (10) ◽  
pp. 6471-6482
Author(s):  
Rafał Kluz ◽  
Andrzej Kubit ◽  
Tomasz Trzepiecinski ◽  
Koen Faes ◽  
Wojciech Bochnowski
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Spot Welding ◽  
Load Capacity ◽  
Base Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

Abstract The welding process used in fabricating thin-walled structures by refill friction stir spot welding (RFSSW) should be characterized by a high strength of welds and high process repeatability which is demonstrated by a small dispersion of the load capacity of the joints. The present work is designed to optimize RFSSW process parameters for 7075-T6 Alclad aluminum alloy sheets used to fabricate aircraft structures. The optimization was performed by scalarization of the objective function using the weighting grades method. The study considers the effect of process parameters, i.e., tool plunge depth, duration of welding, tool rotational speed, on the tensile/shear strength of the joints, and dispersion of the load capacity. It was found that it was possible to choose the optimal welding parameters taking into account maximization of the load capacity and minimization of the dispersion of the joint strength via a best compromise between the tool rotational speed ensuring adequate plasticization of the base material and the duration of welding ensuring that a fine-grained joint microstructure is obtained.

Experimental Investigation on Refill Friction Stir Spot Welding Process of Aluminum Alloys

2013 ◽  
Vol 345 ◽  
pp. 243-246 ◽  
Author(s):  
Hong Gang Yang ◽  
Hai Jun Yang
Keyword(s):  
Aluminum Alloys ◽  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Welding Time ◽  
Welding Quality ◽  
Tensile Shear ◽  
Rotating Speed ◽  
Friction Stir

With the growing demand for lightweight reduction and environment protection, lightweight materials like aluminum and magnesium alloys have been widely applied in the automotive and aerospace industry. Being a solid state welding process, refill friction stir spot welding (RFSSW) is suitable for spot joining lightweight metals. In the present paper, the mechanical properties and microstructure of the RFSSW joints of 6061-T6 aluminum alloys were investigated. The influence of welding parameters, such as plunge depth, rotating speed and welding time, on tensile-shear strength was conducted through experiments. It is found that the tensile-shear strength is increased with the increase of plunge depth, rotating speed and welding time. And welding time is found to be an important key factor which affects welding quality. Research results can provide guidance for welding parameters optimization and welding quality promotion of RFSSW process of aluminum alloys.

Sign in / Sign up

Export Citation Format

Share Document