Microstructure, mechanical and functional properties of refill friction stir spot welds on multilayered aluminum foils for battery application

Gera, Dennis; Fu, Banglong; Suhuddin, U.F.H.; Plaine, Athos Henrique; Alcântara, N.G.; Santos, Jorge F. dos; Klusemann, Benjamin

doi:10.1016/j.jmrt.2021.06.017

Cited by 26 publications

(15 citation statements)

References 28 publications

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“…They suggested that the worn shoulder surface reduced the lap shear strength of the joints while all the tested welds surpassed the minimum standard lap shear strength requirements for aeronautical applications [80]. Numerous studies are available in the literature investigating the RF-SSW of various aluminum alloys such as AA7075 [95][96][97], AA7050 [98], AA2024 [99,100], AA2198 [80], AA2014 [101], AA6061 [102,103], AA2219 [93], dissimilar Al alloys [102,104], dissimilar Al/steel [105], Mg alloys [9,106,107], dissimilar Mg, and steel [7].…”

Section: Friction Stir Spot Weldingmentioning

confidence: 99%

“…First flight of the Eclipse 500 was on 26 August 2002 in which FSW was used to weld the cabin skins, aft fuselage skins, upper and lower wing skins, side cockpit skins and the engine beam [100]. This required the Eclipse Aviation Corporation in collaboration with MTS System Corporation to develop a special FSW system for thin-gauge aerospace aluminum structures with complex contours.…”

Section: Fsw Machine For Eclipse Productionmentioning

confidence: 99%

“…One of the welding head axes provided rotation and the other provided pitch. The weld head consisted of a hydraulic spindle motor, a threedegrees-of-freedom load cell, an actuated sensing ring and a patent pending independent spindle axis [100]. To control the pin penetration to ~0.025 mm, a spindle actuator was incorporated to meet one of the main requirements for Eclipse structure manufacturing.…”

Section: Fsw Machine For Eclipse Productionmentioning

confidence: 99%

See 2 more Smart Citations

Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

et al. 2023

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The use of the friction stir welding (FSW) process as a relatively new solid-state welding technology in the aerospace industry has pushed forward several developments in different related aspects of this strategic industry. In terms of the FSW process itself, due to the geometric limitations involved in the conventional FSW process, many variants have been required over time to suit the different types of geometries and structures, which has resulted in the development of numerous variants such as refill friction stir spot welding (RFSSW), stationary shoulder friction stir welding (SSFSW), and bobbin tool friction stir welding (BTFSW). In terms of FSW machines, significant development has occurred in the new design and adaptation of the existing machining equipment through the use of their structures or the new and specially designed FSW heads. In terms of the most used materials in the aerospace industry, there has been development of new high strength-to-weight ratios such as the 3rd generation aluminum–lithium alloys that have become successfully weldable by FSW with fewer welding defects and a significant improvement in the weld quality and geometric accuracy. The purpose of this article is to summarize the state of knowledge regarding the application of the FSW process to join materials used in the aerospace industry and to identify gaps in the state of the art. This work describes the fundamental techniques and tools necessary to make soundly welded joints. Typical applications of FSW processes are surveyed, including friction stir spot welding, RFSSW, SSFSW, BTFSW, and underwater FSW. Conclusions and suggestions for future development are proposed.

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Section: Friction Stir Spot Weldingmentioning

confidence: 99%

Section: Fsw Machine For Eclipse Productionmentioning

confidence: 99%

Section: Fsw Machine For Eclipse Productionmentioning

confidence: 99%

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Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

et al. 2023

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“…RFSSW joints have three fracture modes when carrying tensile-shear loads: plug fracture, shear-plug fracture and shear fracture [15,16]. It can be seen in Figure 7(a) that when the conventional sleeve is used, the tensile-shear fracture mode of the weld is the shear-plug fracture mode.…”

Section: Tensile-shear Testing and Fracture Behaviourmentioning

confidence: 99%

Effect of tool geometry on hook formation and mechanical properties of refill friction stir spot welding in alclad 2A12-T42 aluminium alloy

Sun

Zhang

et al. 2023

Science and Technology of Welding and Joining

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Three sleeve structures (conventional sleeve, threaded sleeve, grooved sleeve) were used for refill friction stir spot welding (RFSSW) of 2A12-T42 aluminium alloy to investigate the effect of sleeve geometry on hook formation and mechanical properties of the joints. The high-pressure area generated during the plunge stage was responsible for the hook formation. Threads and grooves sleeves not only enhanced the mixing effect but inhibited the hook formation by breaking up the alclad layer or promoting the downward material flow, respectively. The welds using a grooved sleeve had the lowest hook height and highest tensile-shear failure load. As the hook height decreased, the upward tendency of crack propagation was suppressed, which confined the propagation paths within the regions of higher hardness.

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“…For ultrathin sheets, the use of xtures is crucial in order to address the topical issues commonly encountered in Re ll FSSW and FSW. Gera et al [11] performed re ll FSSW to welding Al 2024-T3 sheets (0.3 mm) to 50 layers aluminum foils (13 µm). Defects such as tearing and ash were not observed, which were mainly attributed to the constraint effect of the clamp.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigation of a Novel Pinless Friction Stir Spot Welding for Al 1060 Sheets

Cao,

Zhang,

Xing

et al. 2023

Preprint

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Pinless Friction Stir Spot Welding (P-FSSW) has potential applications in joining ultrathin sheets of thickness 1mm or less. However, two issues namely sheet tearing and weak material intermixing hinder the widespread adoption of P-FSSW in manufacturing fields. This paper proposed the Closed Pinless Friction Stir Spot Welding (CP-FSSW) technique to address these issues. In this study, the CP-FSSW process was performed on Al 1060 alloys, and investigated through experimental observation and numerical modelling. The experimental results show that sound joints without sheet tearing and partially bonded interface defects were achieved. Even a small plunge depth of 0.03 mm resulted in significant deformation of the materials, with the depth of the stir zone being approximately 51 times the plunge depth. Increasing the plunge depth to 0.05 mm or 0.07 mm at a dwelling time of 2 s effectively suppress the formation of hook defect, which was beneficial to the tensile shear load of the joints. Simulations indicate that the morphology of the hook defects at different plunge depth was highly dependent on the effective plastic strain.

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Microstructure, mechanical and functional properties of refill friction stir spot welds on multilayered aluminum foils for battery application

Cited by 26 publications

References 28 publications

Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

Effect of tool geometry on hook formation and mechanical properties of refill friction stir spot welding in alclad 2A12-T42 aluminium alloy

Experimental and Numerical Investigation of a Novel Pinless Friction Stir Spot Welding for Al 1060 Sheets

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