Determining Optimum Shear Strength of Friction Stir Spot Welding Parameters of AA1050/C10100 Joints

Abstract

In this paper, lap joint of 2 mm thickness AA1050 sheets and C10100 sheets using different process parameters were investigated. Experimental plan is designed according to response surface methodology (RSM) where: tool rotation speed, plunge depth and dwell time vary between 500 and 2500 rpm, 2.1 and 3.7 mm and 0 and 8 s respectively. The main affecting and interaction process parameters are evaluated using analysis of variance (ANOVA) methodolgy. Mathematical models describing the relationship between welding parameters and shear failure load (SFL) are developed and the optimal FSSW parameters are specified. Design expert software is used for optimization of friction stir spot welding process parameters using response graphs and contour plots. With 95% confidence level, shear failure load of the dissimilar Al 1050-Cu 10100 joints are predicted using the developed empirical relations. It is found that the optimal results of the SFL is close to the optimal solution obtained from the mathematical model with less than 4% discrepancy.

Computer Simulation of Heating Cycle of Aluminum Alloys Using Friction Stir Welding Technology

“…It is necessary to expect that the microstructure will not be homogeneous throughout the entire weld, that may consist of different microstructural areas (see Fig. 2) [8].…”

Prediction of Tensile Shear Fracture Load of Friction Stir Spot‐Welded AA2024‐T3/HCS Dissimilar Joints

“…Taguchi and complete factorial design were used to optimize the process parameters. Habibizadeh et al [14] investigated the optimum shear strength of friction stir spot welding parameters of AA1050/C10100. The primary and interaction of FSSW parameters were obtained by analysis of variance.…”

“…NSGA-II method was selected to determine the Pareto front and subsequently choose the best possible solutions. Many researchers throughout the globe have used DOE to improve FSSW parameters in both similar and dissimilar alloys, different Al alloys [14], and aluminum-steel [15]. However, no attempt has yet been made to construct empirical correlations to forecast the ability of aluminum and car-bon steel joints to bear tensile shear fracture load-carrying capacities.…”

REW Application Possibilities for the Production of Combined Metal - Plastic Joints

“…At present, when joining thin sheets made of different metal materials, fusion welding technologies like resistance element welding (REW) or resistance spot welding (RSW) are usually used, but solid-state joining processes can also be applied [1,2,3]. The REW technology is used especially in the production of overlap joints on car bodies where it is applied to join, for example, steel stampings with an aluminum alloy [4,5,6,7].…”