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

Novel ultra-high-strength aluminum alloys provide enormous lightweighting potential for modern car body design. However, joining such alloys can be challenging. Refill friction stir spot welding is a solid-state joining process that provides fundamental advantages compared to conventional joining te...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2017-10, Vol.92 (9-12), p.4213-4220
Main Authors: Santana, L. M., Suhuddin, U.F.H., Ölscher, M. H., Strohaecker, T. R., dos Santos, J. F.
Format: Article
Language:English
Subjects:
Alloys
Aluminum alloys
Aluminum base alloys
Automotive bodies
CAE) and Design
Computer-Aided Engineering (CAD
Design of experiments
Design optimization
Engineering
Friction
Friction stir welding
High strength alloys
Industrial and Production Engineering
Joining
Magnesium
Magnesium base alloys
Mechanical Engineering
Mechanical properties
Media Management
Microstructure
Optimization
Original Article
Silicon
Spot welding
Variance analysis
Weight reduction
Welded joints
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Summary:Novel ultra-high-strength aluminum alloys provide enormous lightweighting potential for modern car body design. However, joining such alloys can be challenging. Refill friction stir spot welding is a solid-state joining process that provides fundamental advantages compared to conventional joining technologies when welding aluminum alloys. This work presents refill friction stir spot welding for joining 3-mm-thick Al-Mg-Si alloys. The welded joints have been optimized for shear load condition by the design of experiment and analysis of variance. The results show that it is possible to obtain welds of relatively thick Al-Mg-Si alloys with good mechanical properties. Microstructure analyses show that rotational speed and plunge depth play important roles in the bonded width and hook height, which affect the mechanical performance of the joint.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-017-0432-9