The optimization of friction spot welding process parameters in AA6181-T4 and Ti6Al4V dissimilar joints

Abstract

a b s t r a c tFriction spot welding is a relatively new solid-state joining process able to produce overlap joints between similar and dissimilar materials. In this study, the effect of the process parameters on the lap shear strength of AA6181-T4/Ti6Al4V single joints was investigated using full-factorial design of experiment and analyses of variance. Sound joints with lap shear strength from 4769 N to 6449 N were achieved and the influence of the main process parameters on joint performance was evaluated. Tool rotational speed was the parameter with the largest influence on the joint shear resistance, followed by its interaction with dwell time. Based on the experimental results following response surface methodology, a mathematical model to predict lap shear strength was developed using a second order polynomial function. The initial prediction results indicated that the established model could adequately estimate joint strength within the range of welding parameters being used. The model was then used to optimize welding parameters in order satisfy engineering demands.

Texture Development and Material Flow Behavior During Refill Friction Stir Spot Welding of AlMgSc

“…[11][12][13][14] HZG proved that refill FSSW creates joints with superior mechanical properties to similar processes. The underlying welding mechanisms, such as the material flow behavior, are still unclear.…”

The effect of changing chemical composition on dissimilar Mg/Al friction stir welded butt joints using zinc interlayer

“…Unlike other welding processes, this technique is characterized by the absence of melting, low temperature and low heat input [11,12]. These properties give rise to the wide application of FSW in dissimilar welding [13][14][15][16][17]. Much work has been carried out on the FSW of Al to Mg in butt and lap joints [18][19][20][21].…”

Process optimization and microstructure analysis in refill friction stir spot welding of 3-mm-thick Al-Mg-Si aluminum alloy

“…Refill FSSW uses a non-consumable tool consisting of a stationary clamping ring, rotating pin and sleeve [3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19]. The sleeve-plunge process variant is presented in Figure 1.…”

“…Compared to conventional fusion welding processes, refill FSSW consumes less energy and produces joints with a good surface finish [4,5]. Some published works [5][6][7][8][9][10][11][12][13][14][15] have reported that refill FSSW has been successfully used to weld relatively thin materials, up to 2-mm-thick, in similar and dissimilar joint combinations with good mechanical properties. In similar joint configuration, the weld strength of the joint is driven by a geometrical feature, denominated hook, and the extension of the welded area [6,7].…”