Abstract
The goal of investigations included in this paper is to determine the effect of welding parameters on the load capacity of joints and an analysis of the defects in welded single-lap joints obtained by the refill friction stir spot welding method. Furthermore, a study is made of the effect of welding parameters on the tensile strength and fracture mode of joints subjected to tensile/pure shear loading. The overlapping friction stir spot welded joints are made of two 7075-T6 aluminium alloy sheets with different thicknesses (1.6 and 0.8 mm). The evaluation of joint quality was done using optical microscopy and scanning electron microscopy. The load capacity of joints is determined in tensile/pure shear loading tests. Microstructural analysis showed that the important parameters affecting the quality of the joints are the duration of welding and tool plunge depth. Depending on the tool plunge depth, three types of joint damage were observed. The test results indicate that incorrect selection of welding process parameters results in defects such as voids, hooks, onion rings and bonding ligament.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Schilling C, dos Santos J (2005) Verfahren und vorrichtung zum verbinden von wenigstens zwei aneinanderliegenden werkstücken nach der methode des reibrührschweißens. Germany Patent DE 19955737B4 10
Bayramoglu M, Esme U, Geren N (2003) Effects of welding parameters on the quality of resistance spot welded SAE 1010 steel sheet. Int J Mater Prod Technol 19:362–373. https://doi.org/10.1504/IJMPT.2003.003229
Simončič S, Podržaj P (2014) The applicability of welding force for spot weld quality assurance. Int J Microstruct Mater Prop 9:422–432. https://doi.org/10.1504/IJMMP.2014.066921
Uematsu Y, Tokaji K (2009) Comparison of fatigue behaviour between resistance spot and friction stir spot welded aluminium alloy sheets. Sci Technol Weld Joi 14:62–71. https://doi.org/10.1179/136217108X338908
Salih OS, Ou H, Sun W, McCartney DG (2015) A review of friction stir welding of aluminum matrix composites. Mater Des 86:61–71. https://doi.org/10.1016/j.matdes.2015.07.071
Lacki P, Więckowski W, Wieczorek P (2015) Assessment of joints using friction stir welding and refill friction stir spot welding methods. Arch Metall Mater 60:2297–2306. https://doi.org/10.1515/amm-2015-0377
European Committee for Electrotechnical Standardization (CENELEC). Friction stir welding—aluminium—part 5: quality and inspection requirements. Brussels: CENELEC (2013) Standard No. EN ISO 25239-5:2013
American Welding Society (AWS). Specification for friction stir welding of Al alloys for aerospace applications. Miami: AWS (2009). Standard No. D17.3/D17.3M:20
Gibson BT, Lammlein DH, Prater TJ, Longhurst WR, Cox CD, Ballun MC, Dharmaraj KJ, Cook GE, Strauss AM (2014) Friction stir welding: process, automation, and control. J Manuf Process 16:56–73. https://doi.org/10.1016/j.jmapro.2013.04.002
Shen Z, Yang X, Zhang Z et al (2013) Microstructure and failure mechanisms of refill friction stir spot welded 7075-T6 aluminum alloy joints. Mater Des 44:476–486. https://doi.org/10.1016/j.matdes.2012.08.026
Venukumar S, Yalagi S, Muthukumaran S (2013) Comparison of microstructure and mechanical properties of conventional and refilled friction stir spot welds in AA 6061-T6 using filler plate. Trans Nonferrous Met Soc China 23:2833–2842. https://doi.org/10.1016/S1003-6326(13)62804-6
Rosendo T, Parra B, Tier MAD, da Silva AAM, dos Santos JF, Strohaecker TR, Alcântara NG (2011) Mechanical and microstructural investigation of friction spot welded AA6181-T4 aluminum alloy. Mater Des 32:1094–1100. https://doi.org/10.1016/j.matdes.2010.11.017
Campanelli LC, Suhuddin UFH, Antonialli AÍS, dos Santos JF, de Alcântara NG, Bolfarini C (2013) Metallurgy and mechanical performance of AZ31 magnesium alloy friction spot welds. J Mater Process Technol 213:515–521. https://doi.org/10.1016/j.jmatprotec.2012.11.002
Zhang Z, Yang X, Zhang J, Zhou G, Xu X, Zou B (2011) Effect of welding parameters on microstructure and mechanical properties of friction stir spot welded 5052 aluminum alloy. Mater Des 32:4461–4470. https://doi.org/10.1016/j.matdes.2011.03.058
Tran VX, Pan J, Pan T (2009) Effects of processing time on strengths and failure modes of dissimilar spot friction welds between aluminum 5754-O and 7075-T6 sheets. J Mater Process Technol 209:3724–3739. https://doi.org/10.1016/j.jmatprotec.2008.08.028
Merzoug M, Mazari M, Berrahal L, Imad A (2010) Parametric studies of the process of friction spot stir welding of aluminium 6060-T5 alloys. Mater Des 31:3023–3028. https://doi.org/10.1016/j.matdes.2009.12.029
Choi DH, Ahn BW, Lee CY, Yeon YM, Song K, Jung SB (2010) Effect of pin shapes on joint characteristics of friction stir spot welded AA5J32 sheet. Mater Trans 51:1028–1032. https://doi.org/10.2320/matertrans.M2009405
Xu Z, Li Z, Ji S, Zhang L (2017) Refill friction stir spot welding of 5083-O aluminium alloy. J Mater Sci Technol. https://doi.org/10.1016/j.jmst.2017.02.011
Zhao Y, Liu H, Yang T, Lin Z, Hu Y (2016) Study of temperature and material flow during friction spot welding of 7B04-T74 aluminium alloy. Int J Adv Manuf Technol 83:1467–1475. https://doi.org/10.1007/s00170-015-7681-2
Li Z, Ji S, Ma Y, Chai P, Yue Y, Gao S (2016) Fracture mechanism of refill friction stir spot-welded 2024-T4 aluminium alloy. Int J Adv Manuf Technol 86:1925–1932. https://doi.org/10.1007/s00170-015-8276-7
Cao JY, Wang M, Kong L, Zhao HX, Chai P (2017) Microstructure, texture and mechanical properties during refill friction stir spot welding of 6061-T6 alloy. Mater Charact 128:54–62. https://doi.org/10.1016/j.matchar.2017.03.023
Zhao YQ, Liu HJ, Chen SX, Lin Z, Hou JC (2014) Effects of sleeve plunge depth on microstructures and mechanical properties of friction spot welded alclad 7B04-T74 aluminium alloy. Mater Des 62:40–46. https://doi.org/10.1016/j.matdes.2014.05.012
Reimann M, Goebel J, Gartner TM, dos Santos JF (2017) Refilling termination hole in AA 2198-T851 by refill friction stir spot welding. J Mater Proc Technol 245:157–166. https://doi.org/10.1016/j.jmatprotec.2017.02.025
Reimann M, Goebel J, dos Santos JF (2017) Microstructure and mechanical properties of keyhole repair welds in AA 7075-T651 using refill friction stir spot welding. Mater Des 132:283–294. https://doi.org/10.1016/j.matdes.2017.07.013
American Society for Testing and Materials (ASTM). Standard practice for microetching metals and alloys. West Conshohocken: ASTM International (2007). Standard no. E407
Liu JT, Zhang YA, Li XW, Li ZH, Xiong BQ, Zhang JS (2014) Thermodynamic calculation of high zinc-containing Al-Zn-Mg-Cu alloy. Trans Nonferrous Met Soc China 24:1481–1487. https://doi.org/10.1016/S1003-6326(14)63216-7
Shen Z, Yang X, Yang S, Zhang Z, Yin Y (2016) Microstructure and mechanical properties of friction spot welded 6061-T4 aluminium alloy. Mater Des 54:766–778. https://doi.org/10.1016/j.matdes.2013.08.021
Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R Rep 50:1–78. https://doi.org/10.1016/j.mser.2005.07.001
Santos TG, Miranda RM, Vilaça P, Teixeira JP, dos Santos J (2011) Microstructural mapping of friction stir welded AA 7075-T6 and AlMgSc alloys using electrical conductivity. Sci Technol Weld Joi 16:630–635. https://doi.org/10.1179/1362171811Y.0000000052
Baek SW, Choi DH, Lee CY, Ahn BW, Yeon YM, Song K, Jung SB (2010) Microstructure and mechanical properties of friction stir spot welded galvanized steel. Mater Trans 51:1044–1050. https://doi.org/10.2320/matertrans.M2009337
Dong H, Chen S, Song Y, Guo X, Zhang X, Sun Z (2016) Refilled friction stir spot welding of aluminum alloy to galvanized steel sheets. Mater Des 94:457–466. https://doi.org/10.1016/j.matdes.2016.01.066
Shen Z, Yang X, Yang S, Zhang Z, Yin Y (2016) Microstructure and mechanical properties of friction spot welded 6061-T4 aluminium alloy. Mater Des 54:766–778. https://doi.org/10.1016/j.matdes.2013.08.021
Yang XW, Fu T, Li WY (2014) Friction stir spot welding: a review on joint macro- and microstructure, property, and process modelling. Adv Mater Sci Eng, 2014, article ID 697170 doi: https://doi.org/10.1155/2014/697170
Zafar A, Awang M, Khan SR, Emamian S (2016) Investigating friction stir welding on thick nylon 6 plates. Weld J 95:210–218
Campanelli LC, Suhuddin UFH, Antonialli AIS, dos Santos JF, de Alcantara NG, Bolfarini C (2013) Metallurgy and mechanical performance of AZ31 magnesium alloy friction spot welds. J Mater Process Technol 213:515–521. https://doi.org/10.1016/j.jmatprotec.2012.11.002
Khan NZ, Khan ZA, Siddiquee AN, Al-Ahmari AM, Abidi MH (2017) Analysis of defects in clean fabrication process of friction stir welding. Trans Nonferrous Met Soc China 27:1507–1516. https://doi.org/10.1016/S1003-6326(17)60171-7
Yuan W, Mishra RS, Webb S, Chen YL, Carlson B, Herling DR, Grant GJ (2011) Effect of tool design and process parameters on properties of Al alloy 6016 friction stir spot welds. J Mater Process Technol 211:972–977. https://doi.org/10.1016/j.jmatprotec.2010.12.014
Pourali M, Abdollah-Zadeh A, Saeid T, Kargar F (2017) Influence of welding parameters on intermetallic compounds formation in dissimilar steel/aluminum friction stir welds. J Alloys Compd 715:1–8. https://doi.org/10.1016/j.jallcom.2017.04.272
Tier MD, Rosendo TS, dos Santos JF, Huber N, Mazzaferro JA, Mazzaferro CP, Strohaecker TR (2013) The influence of refill FSSW parameters on the microstructure and shear strength of 5042 aluminium welds. J Mater Process Technol 213:997–1005. https://doi.org/10.1016/j.jmatprotec.2012.12.009
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kubit, A., Bucior, M., Wydrzyński, D. et al. Failure mechanisms of refill friction stir spot welded 7075-T6 aluminium alloy single-lap joints. Int J Adv Manuf Technol 94, 4479–4491 (2018). https://doi.org/10.1007/s00170-017-1176-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-1176-2