Journal
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
Volume 42A, Issue 5, Pages 1266-1282Publisher
SPRINGER
DOI: 10.1007/s11661-010-0514-x
Keywords
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Funding
- EPSRC [EP/G022402/1]
- Friction Joining-Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications [EP/G022402/1]
- FP6 Marie Curie Transfer of Knowledge scheme [MTKD-CT-2006-039546]
- EPSRC [EP/G022402/1, EP/H020047/1] Funding Source: UKRI
- Engineering and Physical Sciences Research Council [EP/G022402/1, EP/H020047/1] Funding Source: researchfish
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The requirement for a probe, or pin, in friction stir spot welding (FSSW) leads to an undesirable keyhole and hooking, which can influence the fracture path and weld strength. Furthermore, the full weld cycle for FSSW is typically longer than ideal for the automotive industry, being 2 to 5 seconds. Here, it is shown that using a novel pinless tool design it is possible to achieve high lap shear strength (similar to 3.4 kN) in thin aluminum sheet (similar to 1 mm thick), with short weld cycle times (< 1 second). Several techniques have been exploited to study the material flow and mechanisms of weld formation in pinless FSSW, including high-resolution X-ray tomography, to understand the role of the tool design and weld parameters. Despite the simple nature of a pinless tool, material flow in the weld zone was found to be surprisingly complex and strongly influenced by surface features on the tool, which greatly increased the penetration of the plastic zone into the bottom sheet. Because of the rapid thermal cycle and high level of grain refinement, the weld zone was found to develop a higher strength than the parent material with little evidence of a heat affected zone (HAZ) after postweld natural aging.
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