A review on resistance spot welding of aluminum alloys

Manladan, Sunusi Marwana; Yusof, Farazila; Ramesh, S.; Fadzil, M. H. Ahmad; Luo, Zhen; Ao, Sansan

doi:10.1007/s00170-016-9225-9

Cited by 165 publications

(54 citation statements)

References 121 publications

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“…Typical alloying elements are tungsten, cobalt, beryllium and silicon metal, which are critical raw materials (CRMs), while chromium, zirconium and molybdenum are near critical elements [ 16 ]. The degradation and consumption of these electrodes, especially for aluminium welding due to the high contact resistance induced by the presence of resistant aluminium oxide layer on the surface of Al alloys is very high [ 17 ]. Therefore, FSSW can lead to a reduction in the consumption of critical raw materials during the spot-welding techniques.…”

Section: Introductionmentioning

confidence: 99%

Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

et al. 2021

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Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.

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Section: Introductionmentioning

confidence: 99%

Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

et al. 2021

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“…For such applications, welded and brazed joints are of interest, because they show good mechanical properties (high temperature strength and fatigue strength) and a higher corrosion resistance in comparison to adhesive joints [7]. The welding techniques like resistance spot welding [8], friction stir welding [9], arc weld-brazing [10] and laser weldbrazing [11] offer a great potential for aluminum alloy/steel joining. However, these processes are often limited to special part geometries and designs of the welded joints.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Thickness of the Reaction Zone in Aluminum/Stainless Steel Brazed Joints on the Mechanical Properties

Fedorov

Uhlig

Wagner

2021

Metals

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The study deals with the characterization of the relationship between the microstructure of the reaction zone and the mechanical properties in the brazed joints of aluminum alloy 3003 and stainless steel AISI 304 in order to determine the influence of the intermetallic layers on the tensile shear strength of the joints. The joints were produced by induction brazing using an AlSi10 filler in an argon atmosphere at a temperature of 600 °C. Due to the local heat input into the liquid brazing filler during a short brazing time, a thin reaction zone is formed in the brazed joints (~1 µm), which ensures good mechanical properties of the joints. In order to observe the growth kinetics of the reaction zone in the brazed joints and to investigate the influence of the thickness of the reaction zone on the mechanical properties of the brazed joints, the joints were aged at temperatures of 200 °C and 500 °C for 6, 48 and 120 h. The results have shown that the thickness of this layer increases to a maximum of 2 µm depending on the duration of the thermal aging at a temperature of 200 °C. The results of the tensile shear strength tests have shown that the brazed joints with this thin layer ensure a high strength. The thermal aging at a temperature of 500 °C influences the growth of the reaction zone in the brazed joints significantly. The total thickness of the reaction zone increases to a maximum of 12 µm during the thermal aging. The results of the tensile shear tests of these joints have shown that the thermal aging at a higher temperature leads to a decrease of the tensile shear strength of the brazed joints to 67% due to the growth of the existing intermetallic layer and the formation of a new intermetallic layer in the reaction zone.

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“…In addition, this process is particularly sensitive to the surface quality of joined elements, hence for aluminum alloys, etching (removal of non-conductive oxides) and ensuring high purity of the welded elements' surface are required. Oxides cause a significant increase in contact resistance and the amount of supplied heat, and as a result, rapid consumption of electrodes [8,9]. Inappropriate welding parameters of RSW may cause the following defects in spot welds: too small a diameter of the weld, lack of penetration, inadequate geometry of the weld, porosity and cracks, and too deep plunging of electrodes in the joined materials [10].…”

Section: Introductionmentioning

confidence: 99%

Effect of Corrosion Protection Method on Properties of RSW and RFSSW Lap Joints Applied in Production of Thin-Walled Aerostructures

et al. 2020

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Aluminum structures, and in particular an element of aerostructures, are strongly exposed to the effects of weather conditions. In the case of using new techniques of joining these structural elements, the selection of proper corrosion protection without losing the required properties of the joint may determine its potential application. This paper presents the results of experimental research concerning the influence of corrosion protection on the microstructure and mechanical strength of resistance spot welded (RSW) and refill friction stir spot welded (RFSSW) joints. The tests were carried out on 2024 T3 aluminum alloy, both sides alcladed. For comparison purposes, the following joints were welded: without any protection, with the primer layer, with anodic oxide coating, and with anodic oxide coating plus sealant between the overlapping surface of the welded metal sheet. The samples were visually inspected, and metallographic and mechanical strength examination was conducted. The test results indicate that the application of the protective layers and its type have an impact on the strength of RSW and RFSSW joints. The use of an adhesive or sealant in welded joints provides an increase in the load capacity of the joint.

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A review on resistance spot welding of aluminum alloys

Cited by 165 publications

References 121 publications

Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Influence of the Thickness of the Reaction Zone in Aluminum/Stainless Steel Brazed Joints on the Mechanical Properties

Effect of Corrosion Protection Method on Properties of RSW and RFSSW Lap Joints Applied in Production of Thin-Walled Aerostructures

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