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Friction stir spot welding of aluminum alloys: A recent review

  • Olatunji Oladimeji Ojo , Emel Taban and Erdinc Kaluc
Published/Copyright: July 3, 2015
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Materials Testing
From the journal Materials Testing Volume 57 Issue 7-8

Abstract

The application prospect of aluminum alloys in aerospace, high speed train manufacturing, shipbuilding and automotive industries is increasing and friction stir spot welding (FSSW) is adjudged to be a non-fusion and suitable joining technology for it. Conversely, friction stir spot welding has challenging attributes such as objectionable FSSW tool pin performance and short life span in mass production stage, creation of crack initiation sites like hook defect, material flow voids and probe hole, as well as restrictions on thickness of materials that can be welded. These challenges have caused a lot of tool profile innovative modifications and technological advancement in friction stir spot welding of aluminum alloys. Nevertheless, some of these vital issues are still unresolved and this notion makes FSSW an evolving solid state joining technology. A succinct view of literature on FSSW of aluminum alloys reveals that most researchers have limited their research to the characterization of microstructure and mechanical properties of aluminum welds; thus leaving a blatant research gap in post-weld tool examinations. Tool wear mechanism and void formation mechanism in FSSW processes as well as characterization of friction stir spot welded aluminum alloys are research areas that need critical examinations. Nevertheless, this publication combines the innovative and recently developed friction stir spot welding technologies of aluminum alloys and assesses their generalized process parameters; it also covers microstructural and mechanical properties of aluminum alloys available in literature. This report classifies FSSW of aluminum alloys based on three criteria namely, probe amendment, shoulder adjustment and complexity of tool movement.

Kurzfassung

Das Interesse an Aluminiumlegierungen in der Luft- und Raumfahrt für Hochgeschwindigkeitszüge, im Schiffbau und in der Automobilindustrie wächst. Das Reibpunktschweißen (FSSW) erweist sich als geeignete Nichtschmelz-Fügetechnologie. Umgekehrt zeigt das Reibpunktschweißen ungenügende Performance des FSSW-Werkzeugpins und eine kurze Lebensdauer in der Serienreife, Positionen für Rissinitiierung, wie Hakendefekt, Werkstoffhohlräume, Pinloch und Einschränkungen hinsichtlich der schweißbaren Materialdicke. Diese Herausforderungen haben viele innovative Veränderungen des Werkzeugprofils und den technologischen Fortschritt des Reibpunktschweißens von Aluminiumlegierungen bewirkt. Dennoch sind einige dieser wichtigen Fragen weiterhin ungelöst und macht das FSSW zu einer sich weiterentwickelnden Festkörperverbindungstechnik. Ein kurzer Literaturüberblick zum FSSW von Aluminiumlegierungen zeigt, dass die meisten Forscher ihre Untersuchungsgrenzen auf die Charakterisierung von Mikrostruktur und die mechanischen Eigenschaften von Aluminiumschweißungen beschränken. Dies führt zu einer offensichtlichen Untersuchungslücke des Werkzeuges nach dem Schweißen. Werkzeugverschleißmechanismen und Hohlraumbildungsmechanismen für FSSW-Prozesse sowie die Charakterisierung von reibpunktgeschweißten Aluminiumlegierungen sind Forschungsbereiche, die eingehende Untersuchungen benötigen. Diese Veröffentlichung verbindet die innovativen und kürzlich entwickelten Technologien des Reibpunktschweißens von Aluminiumlegierungen und bewertet die allgemeinen Prozessparameter; sie umfasst auch die in der Literatur bekannten mikrostrukturellen und mechanischen Eigenschaften von Aluminiumlegierungen. Dieser Bericht klassifiziert das FSSW von Aluminiumlegierungen auf Basis dreier Kriterien, wie Pinänderung, Schulteranpassung und Komplexität der Werkzeugbewegung.

§Correspondence Address Dr. Emel Taban, Kocaeli University, Engineering Faculty, Dept. of Mechanical Engineering, 41380, Kocaeli, Izmit, Turkey, E-mail:

Olatunji Oladimeji Ojo, born in 1983, has worked as a research assistant from 2010–2012 and presently holds the position of Assistant Lecturer at The Federal University of Technology Akure, Ondo State, Nigeria. He obtained his BS in Mechanical Engineering and MSc in Production Engineering option from the school of engineering and engineering technology, The Federal University of Technology, Akure, Nigeria in 2008 and 2012, respectively. Currently, he is a PhD student in the Department of Mechanical Engineering, Kocaeli University, Turkey under the supervision of Assoc. Prof. Dr. Emel Taban. His current research interest covers welding engineering technologies and material characterizations.

Dr. Emel Taban, born in 1980, received her BS, MSc and PhD in Mechanical Engineering in 2002, 2004 and 2007, respectively. She has been working as Associate Professor in the Department of Mechanical Engineering of Kocaeli University, Turkey and is the Vice Director of the Welding Research Center since 2012. Her major interests and expertise include welding and weldability of stainless steels, high alloyed steels and aluminum alloys using conventional and advanced welding processes.

Prof. Erdinc Kaluc, born in 1958, received his BS, MSc and PhD in Mechanical Engineering in 1980, 1982 and 1988, respectively. He has 30 years of experience in welding metallurgy and welding of stainless steels, HSLA steels and aluminum alloys. He has been working as Professor in the Department of Mechanical Engineering of the University of Kocaeli, Turkey and serves as Director of the Welding Research Center.

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Published Online: 2015-07-03
Published in Print: 2015-07-15

© 2015, Carl Hanser Verlag, München

Articles in the same Issue

  1. Fachbeiträge/Technical Contributions
  2. Oxidation behavior of 26Cr-16Ni and AISI 309 austenitic stainless steels in air flow at 1,173 K
  3. Temperature effects on tensile properties of laser sintered polyamide 12
  4. Friction stir spot welding of aluminum alloys: A recent review
  5. Numerical simulation and experimental validation of angular distortion and residual stresses in a T-joint
  6. Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets
  7. Testing of pipe sections
  8. Effect of Ti-Al-O inclusions on the formation of intragranular acicular ferrite
  9. Impact behavior of multi-layer carbon skin composite sandwich panels with 3D spacer fabric
  10. Effect of sintering temperature on transverse rupture strength of hot pressed Cu-TiC composites
  11. Grey-based fuzzy algorithm for the optimization of the ball burnishing process
  12. Analysis of influential factors for ultrasonic disc size evaluation
  13. Evaluation of double channel GMAW fillet welds of low carbon steel using solid wire
  14. Friction behavior of granite powder added brake pads
  15. Prediction of the elastic modulus of SWCNT/epoxy composite based on the micromechanics
  16. Modernization of a surface grinding machine with a novel ball screw drive
  17. Machining of an involute worm gear drive using the surface definition procedure
https://doi.org/10.3139/120.110752

Articles in the same Issue

  1. Fachbeiträge/Technical Contributions
  2. Oxidation behavior of 26Cr-16Ni and AISI 309 austenitic stainless steels in air flow at 1,173 K
  3. Temperature effects on tensile properties of laser sintered polyamide 12
  4. Friction stir spot welding of aluminum alloys: A recent review
  5. Numerical simulation and experimental validation of angular distortion and residual stresses in a T-joint
  6. Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets
  7. Testing of pipe sections
  8. Effect of Ti-Al-O inclusions on the formation of intragranular acicular ferrite
  9. Impact behavior of multi-layer carbon skin composite sandwich panels with 3D spacer fabric
  10. Effect of sintering temperature on transverse rupture strength of hot pressed Cu-TiC composites
  11. Grey-based fuzzy algorithm for the optimization of the ball burnishing process
  12. Analysis of influential factors for ultrasonic disc size evaluation
  13. Evaluation of double channel GMAW fillet welds of low carbon steel using solid wire
  14. Friction behavior of granite powder added brake pads
  15. Prediction of the elastic modulus of SWCNT/epoxy composite based on the micromechanics
  16. Modernization of a surface grinding machine with a novel ball screw drive
  17. Machining of an involute worm gear drive using the surface definition procedure
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