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

Authors

  • M. A. Tashkandi Mechanical Engineering Department, Engineering College, Northern Border University, Arar, Saudi Arabia
  • J. A. Al-jarrah Mechanical Engineering Department, Engineering College, Northern Border University, Arar, Saudi Arabia
  • M. Ibrahim Mechanical Engineering Department, Engineering College, Northern Border University, Arar, Saudi Arabia

Abstract

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.

Keywords:

friction stir spot welding, aluminum alloys, mechanical properties

Downloads

Download data is not yet available.

References

R. Hancock, “Friction welding of aluminum cuts energy cost by 99%”, Welding Journal, Vol. 83, p. 40, 2004

S. Toshya, M. Kenzo, Y. W. Shyuhei, I. Kenji, "Friction stir spot welding of pure aluminum sheet in view of high temperature deformation", Transactions of JWRI, Vol. 40, pp.1-5, 2011

W. M. Thomas, E. D. Nicholas, J. D. Needham, M. G. Murch, P. Templesmith, C. J. Dawes, (1991/1995) G.B. Patent Application No. 9125978.8, Dec. 1991; U.S. Patent No. 5460317, Oct. 1995

S. Baek, D. Choi1, C. Lee, B. Ahn, Y. Yeon, K. Song, S. Jung, “Structure–properties relations in friction stir spot welded low carbon steel sheets for light weight automobile body”, Materials Tranactions, Vol. 5, No. 2, pp. 399-403, 2010 DOI: https://doi.org/10.2320/matertrans.M2009300

R. Qiu, C. Iwamoto, S. Satonaka, “Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate”, J. Mater. Process. Technol., Vol. 209, pp. 4186-4193, 2009

Y. C. Chen, H. Farid, P. B. Prangnell, “Feasibility study of short cycle time friction stir spot welding thin sheet Al to un-galvanised and galvanized steel”, 8th International Friction Stir Welding Symposium, Timmendorfer Strand, Germany, May 18–20 , 2010

R. S. Mishra, M. W. Mahoney (eds), Friction stir welding and processing, ASM International,, 2007

C. Connolly, “Friction spot joining in aluminum car bodies”, Ind. Robot, Vol.34, pp. 17-23, 2007 DOI: https://doi.org/10.1108/01439910710718397

R. Qiu, C. Iwamoto, S. Satonaka, “Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate”, J. Mater. Process. Technol., Vol. 209, pp. 4186-4191, 2009 DOI: https://doi.org/10.1016/j.jmatprotec.2008.11.003

Y. S. Sato, A. Shiota, H. Kokawa, S. Nakagawa, K. Miyamoto, “Effect of microstructure on cross tension strength in dissimilar friction stir spot welds of Al alloy and Zn-coated steel”, Preprints Nation. Meeting Japan. Weld. Soc. Vol. 84, p. 202, 2009

Y. C. Chen, T. Komazaki, Y. G. Kim, T. Tsumura, K. Nakata, “Interface microstructure study of friction stir lap joint of AC4C cast aluminum alloy and zinc-coated steel”, Mater. Chem. Phys. Vol. 111 pp. 375-380, 2008 DOI: https://doi.org/10.1016/j.matchemphys.2008.04.038

P. Bala Srinivasan, M. P. Satish Kumar, “Microstructural and electrochemical characterization of a thin-section dissimilar stainless steel weld joint”, Mater. Chem. Phys., Vol. 115, pp. 179-184, 2009 DOI: https://doi.org/10.1016/j.matchemphys.2008.11.044

P. Lin, S. Lin, J. Pan, T. Pan, L. Nicholson, M. Garman, “Microstructures and Failure Mechanisms of Spot Friction Welds in Lap-Shear Specimens of aluminum 6111-T4 Sheets”, 2004 SAE World Congress, USA, 2004 DOI: https://doi.org/10.4271/2004-01-1330

T. Pan, A. Joaquin, E. Wilkosz, L. Reatherford, J. Nicholson, Z. Feng, M. Santella, “Spot Friction Welding for Sheet Aluminum Joining”, 5th International Symposium on Friction Stir Welding, The Welding Institute, Metz, France, Paper No. 11A-1, 2004

D. Mitlin, V. Radmilovic, T. Pan, Z. Feng, M. Santella, “Structure-Properties Relations in Spot Friction Welded 6111 T4 Aluminum”, TMS 2005 Annual Meeeting, San Francisco, 2005

A. Gerlich, G. Avramovic-Cingara, T.H. North. “Stir Zone Microstructure and Strain Rate during Al 7075-T6 Friction Stir Spot Welding”. Metallurgiccal and Materials Transactions, Vol. 37A, pp. 2773-2786, 2006 DOI: https://doi.org/10.1007/BF02586110

A. Gerlich, M. Yamamoto, “Local melting and tool slippage during friction stir spot welding of Al-alloys”, Joining Science and Technology, Vol. 43, pp. 2-11, 2008 DOI: https://doi.org/10.1007/s10853-007-1791-7

R. Karthikeyan, V. Balasubramanian. “Statistical Optimization and Sensitivity Analysis of Friction Stir Spot Welding Process Parameters for Joining AA 7075 Aluminum Alloy”, Experimental Techniques. Vol. 37, pp. 6-15, 2011 DOI: https://doi.org/10.1111/j.1747-1567.2011.00746.x

N. Pathak, K. Bandyopadhyay, M. Sarangi, S. K. Panda, “Microstructure and Mechanical Performance of Friction Stir Spot-Welded Aluminum-5754 Sheets”, Journal of Materials Engineering and Performance. Vol. 22, pp. 131-144, 2013 DOI: https://doi.org/10.1007/s11665-012-0244-x

S. Babu, V. S. Sankar, G. D. J. Ram, P. V. Venkitakrishnan, G. M. Reddy, K. P. Rao, “Microstructures and Mechanical Properties of Friction Stir Spot Welded Aluminum Alloy AA2014”, Journal of Materials and Performance, Vol. 22, pp. 71-84, 2013 DOI: https://doi.org/10.1007/s11665-012-0218-z

A. Gerlich, P. Su, T. H. North, “Tool penetration during friction stir spot welding of Al and Mg alloys”, Journal of Material Science, Vol. 40, pp. 6473-6481, 2005 DOI: https://doi.org/10.1007/s10853-005-1568-9

Z. Feng, M. Santella, S. David, R. Steel, S. Packer, T. Pan, M. Kuo, R. Bhatnagar, “Friction Stir Spot Welding of Advanced High-Strength Steels-A Feasibility Study”, Proceeding of the 2005 SAE Congress, Detroit, USA, 2005 DOI: https://doi.org/10.4271/2005-01-1248

R. Sakano, K. Murakami, K. Yamashita, T. Hyoe, M. Fujimoto, M. Inuzuka, Y. Nagao, H. Kashiki, , “Development of Spot FSW Robot System for Automobile Body Members”, Proceedings of the 3rd. International Symposium of Friction Stir Welding, Kobe, Japan, 2001

M. Zhou, S. J. Hu, H. Zhang, “Critical Specimen Size for Tensile-Shear Testing of Steel Sheets”, Welding Research Supplements, pp. 305-313, 1999

M. K. Abbas, "Effect of aging time on the mechanical properties of friction stir spot welding of Al-Alloy (AA-2024)”, Inter. J. of Eng. Res. and Appl., Vol. 2, No. 3, pp. 1366-1374, 2012

C. Jonckheere, B. Neester, C. Cassiers, M. Delhaye, A. Simar, “Fracture and mechanical properties of friction stir spot welds in 6063-T6 aluminum alloy”, Int. J. Adv. Manuf. Tech., Vol. 62, pp. 569-575, 2012 DOI: https://doi.org/10.1007/s00170-011-3795-3

M. K. Kulekci, A. Sik, E. Kaluc, “Effects of tool rotation and pin diameter on fatigue properties of friction stir welded lap joints”, Int. J. Adv. Manuf. Tech., Vol. 36, pp. 877-882, 2008 DOI: https://doi.org/10.1007/s00170-006-0901-z

S. Toshiya, M. Kenzo, Y. Shyuhei, I. kenji, “Friction stir spot welding of pure aluminum sheet in view of high temperature deformation”, Transaction of JWRI, Vol. 40, No. 2, pp.1-5, 2011

W. Yuan, R. S. Mishra, S. Webb, Y. L. Chen, B. Carlson, D. R. Herling, G. J. Grant, “Effect of tool design and process parameters on properties of Al alloy 6016 friction stir spot welds”, Journal of Materials Processing Technology, Vol. 211, No. 6, pp. 972–977, 2011 DOI: https://doi.org/10.1016/j.jmatprotec.2010.12.014

M. K. Kulekci, “Effects of Process Parameters on Tensile Shear Strength of Friction Stir Spot Welded Aluminum Alloy (EN AW 5005)”, Archives of Metallurgy and Materials, Vol. 59, No. 1, pp. 221-224, 2014 DOI: https://doi.org/10.2478/amm-2014-0035

M. K. Bilici, "Effect of tool geometry on friction stir spot welding of polypropylene sheets”, Express Polymer Letters, Vol. 6, No. 1, pp. 805-813, 2012 DOI: https://doi.org/10.3144/expresspolymlett.2012.86

M. K. Bilici, A. I. Yukler, “Influence of tool geometry and process parameters on macrostructure and static strength in friction stir spot welded polyethylene sheets”, Materials and Design, Vol. 33, pp. 145–152, 2012 DOI: https://doi.org/10.1016/j.matdes.2011.06.059

T. Y. Pan, “Friction Stir Spot Welding (FSSW)–A Literature Review”, 2007 World Congress, SAE Int. Detroit, Mich., USA, 2007 DOI: https://doi.org/10.4271/2007-01-1702

X. Y. Wang, T. Fu, W. Y. Li, “Friction spot welding: a review on joints macro and microstructure, properties, and process modeling”, Adv. in Mater. Sci. and Engineering, pp. 1-11, 2014 DOI: https://doi.org/10.1155/2014/697170

V. X. Tran, J. Pan, T. Pan, “Effects of processing time on strengths and failure modes of dissimilar spot friction welds between aluminum 5754-O and 7075-T6 sheets”, Journal of Materials Processing Technology, Vol. 209, No. 8, pp. 3724–3739, 2009 DOI: https://doi.org/10.1016/j.jmatprotec.2008.08.028

Downloads

How to Cite

[1]
M. A. Tashkandi, J. A. Al-jarrah, and M. Ibrahim, “Spot Welding of 6061 Aluminum Alloy by Friction Stir Spot Welding Process”, Eng. Technol. Appl. Sci. Res., vol. 7, no. 3, pp. 1629–1632, Jun. 2017.

Metrics

Abstract Views: 898
PDF Downloads: 328

Metrics Information
Bookmark and Share

Most read articles by the same author(s)