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Optimization of the intermediate layer friction stir spot welding process

The International Journal of Advanced Manufacturing Technology volume 104, pages 993–1004 (2019)Cite this article

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.

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Funding

Partial support from Ozyegin University research fund is acknowledged.

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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

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  1. Isam Jabbar Ibrahim
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  2. Guney Guven Yapici
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Correspondence to Guney Guven Yapici.

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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

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

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