Friction Stir Spot Welding of Aluminum and Copper: A Review

Li, Mingshen; Zhang, Chaoqun; Wang, Dayong; Zhou, Li; Wellmann, Daniel; Tian, Yingtao

doi:10.3390/ma13010156

Cited by 48 publications

(21 citation statements)

References 89 publications

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“…In 1991, friction stir welding (FSW) was initially introduced by TWI in the United Kingdom as a newly developed solid-state welding process, particularly for joining aluminum alloys with specific requirements that should be fulfilled [1,2]. Then friction stir spot welding (FSSW) was developed as one of its variant for local joining of similar and dissimilar sheets [3][4][5][6][7][8][9] as a promising technique with similarities to the basic concepts of linear FSW with a specific requirement where no lateral movement of the tool is required [10]. More interestingly, the rotating tool pierces the sheets that are being welded and then produces a stir zone.…”

Section: Introductionmentioning

confidence: 99%

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

et al. 2022

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In the current study, a 2 mm thick low-carbon steel sheet (A283M—Grade C) was joined with a brass sheet (CuZn40) of 1 mm thickness using friction stir spot welding (FSSW). Different welding parameters including rotational speeds of 1000, 1250, and 1500 rpm, and dwell times of 5, 10, 20, and 30 s were applied to explore the effective range of parameters to have FSSW joints with high load-carrying capacity. The joint quality of the friction stir spot-welded (FSSWed) dissimilar materials was evaluated via visual examination, tensile lap shear test, hardness test, and macro- and microstructural investigation using SEM. Moreover, EDS analysis was applied to examine the mixing at the interfaces of the dissimilar materials. Heat input calculation for the FSSW of steel–brass was found to be linearly proportional with the number of revolutions per spot joint, with maximum heat input obtained of 11 kJ at the number of revolutions of 500. The temperature measurement during FSSW showed agreement with the heat input dependence on the number of revolution. However, at the same revolutions of 500, it was found that the higher rotation speed of 1500 rpm resulted in higher temperature of 583 °C compared to 535 °C at rotation speed of 1000 rpm. This implies the significant effect for the rotation speed in the increase of temperature. The macro investigations of the friction stir spot-welded joints transverse sections showed sound joints at the different investigated parameters with significant joint ligament between the steel and brass. FSSW of steel/brass joints with a number of revolutions ranging between 250 to 500 revolutions per spot at appropriate tool speed range (1000–1500 rpm) produces joints with high load-carrying capacity from 4 kN to 7.5 kN. The hardness showed an increase in the carbon steel (lower sheet) with maximum of 248 HV and an increase of brass hardness at mixed interface between brass and steel with significant reduction in the stir zone hardness. Microstructural investigation of the joint zone showed mechanical mixing between steel and brass with the steel extruded from the lower sheet into the upper brass sheet.

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Section: Introductionmentioning

confidence: 99%

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

et al. 2022

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“…FSSW process is considered a promising way to weld aluminum alloys because it effectively avoids defects in the conventional fusion welding technology [12,13]. The FSSW process is similar to friction stir welding (FSW), except for no transverse movement of the welding tool [14]. The biggest limitation of conventional FSSW (CFSSW) is the keyhole, which is not only aesthetically undesirable but also decreases the bonding area of the weld [15,16].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Performances Analyses on Probeless Friction Stir Spot Welds of AA6061-T6 Aluminum Sheets

Chen

Zitao

et al. 2021

Preprint

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Probeless friction stir spot welding (PFSSW) is a variation of conventional friction stir spot welding (CFSSW), which solves the keyhole defect in CFSSW welds. In this work, four types of probeless tools were designed based on helix and spiral feature: small curvature helix (involute tool, IT), large curvature helix (archimedes tool, AT), spiral line (scroll tool, ST) and no feature (flat tool, FT). AA6061-T6 sheets with a thickness of 1.5 mm were welded using the designed probeless welding tools. The effect of tool shapes on the microstructure and mechanical properties of friction stir spot welded AA 6061-T6 aluminum alloy sheets was investigated using different rotational speeds, plunging depths and dwell times. The Taguchi method was utilized to obtain the optimal welding parameter combination for the four tools. And, the tensile-shear mechanical properties of FSSW specimens were characterized under the optimal parameters. The results show that a basin-shaped profile appeared in the weld metallography using the groove tools. The tensile shear failure load (TSFL) of IT (~6.97 kN) was higher than that of ST (~6.49 kN), AT (~6.19 kN) and FT (~5.67 kN), sequentially. Three different fracture modes, interfacial fracture, plug fracture and mixed-mode fracture were observed in the tensile-shear tests of weld specimens.

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“…Instead, friction stir welding resides in focus of many recent works around dissimilar Al-Cu joints [22,23,25,[27][28][29][30][31]. Apart from the conventional friction stir welding (path process variant), there are further process variants such as refill fiction stir spot welding [32][33][34] which is developed to replace resistance spot welding in car body applications as well as the classical friction stir spot welding, [20,[35][36][37][38][39][40], which are very promising. The abovementioned process variant-friction stir spot welding (FSSW)-is especially attractive because of the easier handling, clamping and the lower process time compared to the path process variant.…”

Section: Introductionmentioning

confidence: 99%

Tool Downscaling Effects on the Friction Stir Spot Welding Process and Properties of Current-Carrying Welded Aluminum–Copper Joints for E-Mobility Applications

Tankoua

Kohler

Bergmann

et al. 2021

Metals

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According to the technical breakthrough towards E-Mobility, current-carrying dissimilar joints between aluminum and copper are gaining an increasing relevance for the automotive industry and thus, coming into focus of many research activities. The joining of dissimilar material in general is well known to be a challenging task. Furthermore, the current-carrying joining components in E-Drive consist of pure aluminum and copper materials with relatively thin sheet thickness, which are thermally and mechanically very sensitive, as well as highly heat and electrically conductive. This results in additional challenges for the joining process. Due to their properties, friction stir welding and especially fiction stir spot welding (FSSW) using pinless tools—i.e., as hybrid friction diffusion bonding process (HFDB) is more and more attractive for new application fields and particularly promising for aluminum–copper joining tasks in E-Mobility. However, the feasibility is restricted because of the relatively high process forces required during friction stir welding. Thus, to fulfill the high process and quality requirements in this above-mentioned application field, further research and process development towards process force reduction are necessary. This work deals with the application of the tool downscaling strategy as a mean of process force reduction in FSSW of thin aluminum and copper sheets for current-carrying applications in E-Mobility, where the components are very sensitive to high mechanical loads. The tool downscaling approach enables constant weld quality in similar process time of about 0.5 s despite reduced process forces and torques. By reducing the tool diameter from 10 mm to 6 mm, the process force could be reduced by 36% and the torque by over 50%. Furthermore, a similar heat propagation behavior in the component is observable. These results provide a good basis for the joining of E-Drive components with thermal and mechanical sensitive sheet materials using the pinless FSSW process.

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Friction Stir Spot Welding of Aluminum and Copper: A Review

Cited by 48 publications

References 89 publications

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

Microstructure and Mechanical Performances Analyses on Probeless Friction Stir Spot Welds of AA6061-T6 Aluminum Sheets

Tool Downscaling Effects on the Friction Stir Spot Welding Process and Properties of Current-Carrying Welded Aluminum–Copper Joints for E-Mobility Applications

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