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Consumable pin-friction stir spot welding of Al-Mg-Si alloy via pre-created hole and refilling: Microstructure evolution, defects, and shear/tensile failure load
University West, Department of Engineering Science, Division of Welding Technology. (KAMPT)ORCID iD: 0000-0002-6820-4312
Department of Materials Science and Engineering, Sharif University of Technology, Tehran (IRN).
2023 (English)In: Proceedings of the Institution of mechanical engineers. Part C, journal of mechanical engineering science, ISSN 0954-4062, E-ISSN 2041-2983, Vol. 237, no 17Article in journal (Refereed) Published
Abstract [en]

Since Al-Mg-Si alloys are widely used in the transportation industry, it is important to produce a sound and robust weld between the sheets of these alloys. The focus of this work is on the tensile-shear and cross-tension strengths of the consumable pin-friction stir spot welds (CP-FSSWs) without an exit-hole between the Al-6061 aluminum sheets. Before welding, a hole was created at the joint region in the base sheets and then, it was filled using a rotating consumable pin. The tensile-shear, cross-tension, and microhardness tests were employed to evaluate the mechanical properties of the spot welds. The results showed that the pre-created hole was entirely filled during the welding process. While a complete bond was formed between the consumable pin and the lateral surface of the hole, there were three distinct regions at the interface of the pin and the bottom of the hole: complete bond, kissing bond, and defects. Enhancement of the tool rotational speed decreased the area of the complete bond in the weld compared to the other regions. A linear relationship existed between the bonding area and weld failure load in the cross-tension test. The proposed relationship approved the impact of the swirly region at the interface of the base sheets on the weld strength. While in the cross-tension test, the weld failure load decreased from ∼2800 to ∼1950 N, it improved from ∼10,500 to ∼12,000 N in the tensile-shear test with enhancement of the tool rotational speed from 700 to 2000 rpm. The hardness measurements demonstrated that there was no common heat affected zone softening after CP-FSSW.  

Place, publisher, year, edition, pages
Sage Publications, 2023. Vol. 237, no 17
Keywords [en]
Aluminum alloys; Friction; Friction stir welding; Heat affected zone; Magnesium alloys; Silicon alloys; Spot welding; Tensile strength; Tensile testing; Al 6061; Base sheet; Consumables; Cross-tension; Failure load; Fracture surfaces; Friction stir spot weld; Friction stir spot welding; Tensile shears; Tension tests; Microstructure
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-19818DOI: 10.1177/09544062231151566ISI: 000922866700001Scopus ID: 2-s2.0-85147590348OAI: oai:DiVA.org:hv-19818DiVA, id: diva2:1796956
Available from: 2023-09-13 Created: 2023-09-13 Last updated: 2024-01-04Bibliographically approved

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Baghdadchi, Amir

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