Friction-Stir Spot Mechanical Joining between Hot-Dip 55% Aluminum–Zinc Alloy-Coated Steel Sheet and A5083 Aluminum Alloy Plate Using Conventional Punching

Abstract

In this study, we fabricated a mechanical joining with spot friction-stirring between an aluminum alloy plate and an aluminum–zinc alloy-coated steel sheet; this was achieved by utilizing a conventional press-punching preprocess. In the preprocessing, a hot-dip 55% aluminum–zinc alloy-coated steel sheet was punched using a press and an inclined surface was generated at the wall of a punched hole due to shear droop. Subsequently, an A5083P-O aluminum alloy plate was positioned against it, and friction stirring was conducted on its rear surface. The hole was filled with the aluminum alloy to generate a mechanical interlock at the tilt of the wall. Further, we evaluated its cross tensile strength (CTS) and tensile shear strength (TSS) and obtained an average CTS and TSS of 368 kN and 1470 kN, respectively.