Exploring a novel chamfered tool design for short duration refill friction stir spot welds of high strength aluminium

Jonathan Draper, Sebastian Fritsche, Sergio de Traglia Amancio-Filho, Alexander Galloway, Athanasios Toumpis

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Abstract

This work investigates refill friction stir spot welded joints of AA2024-T3 aluminium alloy, produced with short welding times between 3 s and 0.75 s. A novel tool geometry that incorporates a chamfer on the inner edge of the shoulder tip is investigated as a means of improving joint quality at short welding times by easing material flow during the refill stage. The influence of shoulder design on weld microstructure, defect formation, material flow, and mechanical properties was assessed. When compared with a standard shoulder geometry, it was found that the introduction of a chamfer on the inner tip edge improved material flow during the refill stage and led to improved material mixing at the weld periphery. The formation of voids in the region of the weld periphery was eliminated and tensile lap-shear strength of the welded joints was increased by 19% to 7.2 kN, and 27% to 8.16 kN, for 0.75 s and 1.5 s duration welds, respectively.
Original languageEnglish
Pages (from-to)5867-5879
Number of pages13
JournalThe International Journal of Advanced Manufacturing Technology
Volume131
Issue number12
Early online date5 Mar 2024
DOIs
Publication statusPublished - 1 Apr 2024

Keywords

  • refill friction stir spot welding
  • weld microstructure
  • spot welding techniques
  • aluminium alloys
  • tool geometry

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