Skip to main content
SpringerLink
Log in

Optimization of the intermediate layer friction stir spot welding process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Friction stir spot welding was performed for joining sheets of 2024 and 6061 aluminum alloys, which is otherwise difficult using conventional welding techniques. The presented approach utilizes an intermediate layer to avoid the keyhole problem. Design of experiment analysis was carried out to evaluate the influence of process parameters. The optimized set of parameters led to the fabrication of sound joints with strength properties exceeding twice the applicable standard requirements as discussed with the evidence of branched hook formations with extensive penetration. Tool rotational speed was determined to be the most significant parameter influencing the mechanical performance. The failure mode revealed itself as sheet tearing-nugget pull out in the joints produced under optimum conditions with various sized dimples apparent on the fracture surface.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Yamamoto M, Gerlich A, North TH, Shinozaki K (2008) Cracking and local melting in Mg-alloy and Al-alloy during friction stir spot welding. Weld World 52:38–46

    Article  Google Scholar 

  2. Kim Y-G, Jo B-J, Kim J-S, Kim I-J (2017) A study on dissimilar welding of aluminum alloy and advanced high strength steel by spot welding process. Int J Precis Eng Manuf 18:121–126

    Article  Google Scholar 

  3. Lei H, Li Y, Carlson BE (2017) Cold metal transfer spot welding of 1 mm thick AA6061-T6. J Manuf Process 28:209–219

    Article  Google Scholar 

  4. Da Silva AAM, Aldanondo E, Alvarez P et al (2011) Mechanical and microstructural investigation of dissimilar resistance and friction stir spot welds in AA5754-H22 and AA6082-T6 Al alloys and 22MnB5 hot-stamped boron steel. Frict Stir Weld Process VI:389–399

    Article  Google Scholar 

  5. Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R Rep 50:1–78. https://doi.org/10.1016/j.mser.2005.07.001

    Article  Google Scholar 

  6. Wang DA, Lee SC (2007) Microstructures and failure mechanisms of friction stir spot welds of aluminum 6061-T6 sheets. J Mater Process Technol 186:291–297. https://doi.org/10.1016/j.jmatprotec.2006.12.045

    Article  Google Scholar 

  7. Badarinarayan H, Yang Q, Zhu S (2009) Effect of tool geometry on static strength of friction stir spot-welded aluminum alloy. Int J Mach Tools Manuf 49:142–148

    Article  Google Scholar 

  8. Sun YF, Fujii H, Takaki N, Okitsu Y (2012) Microstructure and mechanical properties of mild steel joints prepared by a flat friction stir spot welding technique. Mater Des 37:384–392

    Article  Google Scholar 

  9. Goodarzi M, Marashi SPH, Pouranvari M (2009) Dependence of overload performance on weld attributes for resistance spot welded galvanized low carbon steel. J Mater Process Technol 209:4379–4384

    Article  Google Scholar 

  10. Bilici MK, Yükler Aİ, Kurtulmuş M (2011) The optimization of welding parameters for friction stir spot welding of high density polyethylene sheets. Mater Des 32:4074–4079

    Article  Google Scholar 

  11. Paidar M, Khodabandeh A, Sarab ML, Taheri M (2015) Effect of welding parameters (plunge depths of shoulder, pin geometry, and tool rotational speed) on the failure mode and stir zone characteristics of friction stir spot welded aluminum 2024-T3 sheets. J Mech Sci Technol 29:4639–4644

    Article  Google Scholar 

  12. Fujimoto M, Koga S, Abe N, Sato YS, Kokawa H (2008) Microstructural analysis of stir zone of Al alloy produced by friction stir spot welding. Sci Technol Weld Join 13:663–670. https://doi.org/10.1179/136217108X347601

    Article  Google Scholar 

  13. Bozkurt Y, Salman S, Çam G (2013) Effect of welding parameters on lap shear tensile properties of dissimilar friction stir spot welded AA 5754-H22/2024-T3 joints. Sci Technol Weld Join 18:337–345. https://doi.org/10.1179/1362171813Y.0000000111

    Article  Google Scholar 

  14. Chu Q, Yang XW, Li WY, Li YB (2016) Microstructure and mechanical behaviour of pinless friction stir spot welded AA2198 joints. Sci Technol Weld Join 21:164–170. https://doi.org/10.1179/1362171815Y.0000000078

    Article  Google Scholar 

  15. Babu S, Sankar VS, Ram GDJ et al (2013) Microstructures and mechanical properties of friction stir spot welded aluminum alloy AA2014. J Mater Eng Perform 22:71–84

    Article  Google Scholar 

  16. Li W, Li J, Zhang Z, Gao D, Wang W, Dong C (2014) Improving mechanical properties of pinless friction stir spot welded joints by eliminating hook defect. Mater Des 62:247–254

    Article  Google Scholar 

  17. Schilling C, dos Santos J (2004) Method and device for joining at least two adjoining work pieces by friction welding U.S. Patent No. 6,722,556. Washington, DC: USPTO

  18. Uematsu Y, Tokaji K, Tozaki Y et al (2008) Effect of re-filling probe hole on tensile failure and fatigue behaviour of friction stir spot welded joints in Al–Mg–Si alloy. Int J Fatigue 30:1956–1966

    Article  Google Scholar 

  19. Sun YF, Fujii H, Takaki N, Okitsu Y (2011) Novel spot friction stir welding of 6061 and 5052 Al alloys. Sci Technol Weld Join 16:605–612

    Article  Google Scholar 

  20. Sun YF, Fujii H, Takaki N, Okitsu Y (2013) Microstructure and mechanical properties of dissimilar Al alloy/steel joints prepared by a flat spot friction stir welding technique. Mater Des 47:350–357

    Article  Google Scholar 

  21. Chen K, Liu X, Ni J (2017) Keyhole refilled friction stir spot welding of aluminum alloy to advanced high strength steel. J Mater Process Technol 249:452–462

    Article  Google Scholar 

  22. Lathabai S, Painter MJ, Cantin GMD, Tyagi VK (2006) Friction spot joining of an extruded Al–Mg–Si alloy. Scr Mater 55:899–902

    Article  Google Scholar 

  23. Elangovan K, Balasubramanian V (2008) Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. J Mater Process Technol 200:163–175

    Article  Google Scholar 

  24. Merzoug M, Mazari M, Berrahal L, Imad A (2010) Parametric studies of the process of friction spot stir welding of aluminium 6060-T5 alloys. Mater Des 31:3023–3028

    Article  Google Scholar 

  25. Li Y, Murr LE, McClure JC (1999) Flow visualization and residual microstructures associated with the friction-stir welding of 2024 aluminum to 6061 aluminum. Mater Sci Eng A 271:213–223

    Article  Google Scholar 

  26. Vural M, Ogur A, Cam G, Ozarpa C (2007) On the friction stir welding of aluminium alloys EN AW 2024-0 and EN AW 5754-H22. Arch Mater Sci Eng 28:49–54

    Google Scholar 

  27. Ibrahim IJ, Yapici GG (2018) Application of a novel friction stir spot welding process on dissimilar aluminum joints. J Manuf Process 35:282–288. https://doi.org/10.1016/j.jmapro.2018.08.018

    Article  Google Scholar 

  28. Tutar M, Aydin H, Yuce C, Yavuz N, Bayram A (2014) The optimisation of process parameters for friction stir spot-welded AA3003-H12 aluminium alloy using a Taguchi orthogonal array. Mater Des 63:789–797

    Article  Google Scholar 

  29. Zarghani F, Mousavizade SM, Ezatpour HR, Ebrahimi GR (2018) High mechanical performance of similar Al joints produced by a novel spot friction welding technique. Vacuum 147:172–186

    Article  Google Scholar 

  30. Gerlich A, Su P, Yamamoto M, North TH (2007) Effect of welding parameters on the strain rate and microstructure of friction stir spot welded 2024 aluminum alloy. J Mater Sci 42:5589–5601

    Article  Google Scholar 

  31. Hosseinzadeh A, Yapici GG (2018) High temperature characteristics of Al2024/SiC metal matrix composite fabricated by friction stir processing. Mater Sci Eng A 731:487–494. https://doi.org/10.1016/j.msea.2018.06.077

    Article  Google Scholar 

  32. American Welding Society (AWS) (2013) Specification for resistance welding for aerospace applications. AWS D17.2M. An American National Standard, Miami

  33. Zhang Z, Yang X, Zhang J, Zhou G, Xu X, Zou B (2011) Effect of welding parameters on microstructure and mechanical properties of friction stir spot welded 5052 aluminum alloy. Mater Des 32:4461–4470

    Article  Google Scholar 

  34. Yang Q, Li X, Chen K, Shi YJ (2011) Effect of tool geometry and process condition on static strength of a magnesium friction stir lap linear weld. Mater Sci Eng A 528:2463–2478

    Article  Google Scholar 

  35. Bozkurt Y, Bilici MK (2013) Application of Taguchi approach to optimize of FSSW parameters on joint properties of dissimilar AA2024-T3 and AA5754-H22 aluminum alloys. Mater Des 51:513–521

    Article  Google Scholar 

  36. Roy RK (2001) Design of experiments using the Taguchi approach: 16 steps to product and process improvement. John Wiley & Sons, New York

  37. Hui YV, Leung LC, Linn R (2001) Optimal machining conditions with costs of quality and tool maintenance for turning. Int J Prod Res 39:647–665

    Article  MATH  Google Scholar 

  38. American Welding Society (AWS) (2007) Specification for automotive weld quality-resistance spot welding of steel. AWS D8.1M. An American National Standard, Miami

  39. Pan T-Y, Santella ML, Blundell N (2009) Friction stir spot welding for structural aluminum sheets. SAE Int J Mater Manuf 2:23–29

    Article  Google Scholar 

  40. Zhou L, Liu D, Nakata K, Tsumura T, Fujii H, Ikeuchi K, Michishita Y, Fujiya Y, Morimoto M (2012) New technique of self-refilling friction stir welding to repair keyhole. Sci Technol Weld Join 17:649–655

    Article  Google Scholar 

  41. Ji SD, Meng XC, Huang RF, Ma L, Gao SS (2016) Microstructures and mechanical properties of 7N01-T4 aluminum alloy joints by active-passive filling friction stir repairing. Mater Sci Eng A 664:94–102. https://doi.org/10.1016/j.msea.2016.03.131

    Article  Google Scholar 

  42. Bakavos D, Prangnell PB (2009) Effect of reduced or zero pin length and anvil insulation on friction stir spot welding thin gauge 6111 automotive sheet. Sci Technol Weld Join 14:443–456

    Article  Google Scholar 

  43. Mitlin D, Radmilovic V, Pan T, Chen J, Feng Z, Santella ML (2006) Structure–properties relations in spot friction welded (also known as friction stir spot welded) 6111 aluminum. Mater Sci Eng A 441:79–96. https://doi.org/10.1016/j.msea.2006.06.126

    Article  Google Scholar 

  44. Pathak N, Bandyopadhyay K, Sarangi M, Panda SK (2013) Microstructure and mechanical performance of friction stir spot-welded aluminum-5754 sheets. J Mater Eng Perform 22:131–144

    Article  Google Scholar 

  45. Chen Y, Ding H, Cai Z, Zhao J, Li J (2016) Effect of initial base metal temper on microstructure and mechanical properties of friction stir processed Al-7B04 alloy. Mater Sci Eng A 650:396–403

    Article  Google Scholar 

  46. Uematsu Y, Tokaji K (2009) Comparison of fatigue behaviour between resistance spot and friction stir spot welded aluminium alloy sheets. Sci Technol Weld Join 14:62–71

    Article  Google Scholar 

  47. Li WY, Fu T, Hütsch L, Hilgert J, Wang FF, dos Santos JF, Huber N (2014) Effects of tool rotational and welding speed on microstructure and mechanical properties of bobbin-tool friction-stir welded Mg AZ31. Mater Des 64:714–720

    Article  Google Scholar 

  48. Klobčar D, Tušek J, Smolej A, Simončič S (2015) Parametric study of FSSW of aluminium alloy 5754 using a pinless tool. Weld World 59:269–281

    Article  Google Scholar 

  49. Tozaki Y, Uematsu Y, Tokaji K (2007) Effect of tool geometry on microstructure and static strength in friction stir spot welded aluminium alloys. Int J Mach Tools Manuf 47:2230–2236

    Article  Google Scholar 

  50. Li Z, Ji S, Ma Y, Chai P, Yue Y, Gao S (2016) Fracture mechanism of refill friction stir spot-welded 2024-T4 aluminum alloy. Int J Adv Manuf Technol 86:1925–1932

    Article  Google Scholar 

  51. Pouranvari M, Asgari HR, Mosavizadch SM, Marashi PH, Goodarzi M (2007) Effect of weld nugget size on overload failure mode of resistance spot welds. Sci Technol Weld Join 12:217–225

    Article  Google Scholar 

  52. Li X, Zhang D, Cheng QIU, Zhang W (2012) Microstructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding. Trans Nonferrous Metals Soc China 22:1298–1306

    Article  Google Scholar 

  53. Song X, Ke L, Xing L, Liu F, Huang C (2014) Effect of plunge speeds on hook geometries and mechanical properties in friction stir spot welding of A6061-T6 sheets. Int J Adv Manuf Technol 71:2003–2010

    Article  Google Scholar 

Download references

Funding

Partial support from Ozyegin University research fund is acknowledged.

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, Ozyegin University, Istanbul, Turkey

    Isam Jabbar Ibrahim & Guney Guven Yapici

  2. Technical Engineering College, Middle Technical University, Baghdad, Iraq

    Isam Jabbar Ibrahim

Authors
  1. Isam Jabbar Ibrahim
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guney Guven Yapici
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Guney Guven Yapici.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ibrahim, I.J., Yapici, G.G. Optimization of the intermediate layer friction stir spot welding process. Int J Adv Manuf Technol 104, 993–1004 (2019). https://doi.org/10.1007/s00170-019-03952-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-03952-3

Keywords

Search

Navigation