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Repairing of exit-hole in friction-stir-spot welded joints for 2024-T4 aluminum alloy by resistance welding

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Abstract

The exit-hole in friction stir spot welded (FSSWed) 2024-T4 aluminum alloy joints was successfully repaired by using a three-phase secondary rectification resistance spot welding machine, which is termed as filling exit-hole based on resistance welding (FEBRW). The filling dynamic behavior of force was recorded by a device monitoring. Optical microscope (OM), electron backscatter diffraction (EBSD), and tensile shear tests and finite element modelling were conducted to investigate the repairing stages and bonding mechanisms of the repaired joints in detail. Results showed that exit-hole was completely filled and repaired experiencing three stages. Metallurgical bonding was achieved between plug and exit-hole wall in two forms, including melting bonding in the middle of the joints and partial diffusion bonding on both the upper and bottom of the joints. The highest tensile shear strength of the repaired joints was 7.43 kN, which was 36.3% higher than that of the as welded joints. Resistance welding paves an efficient way to repair the exit-hole in FSSWed joints.

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Acknowledgement

This work was financially supported by the National Natural Science Foundation of China (No. 51874179).

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Authors and Affiliations

  1. School of Aeronautical Manufacturing and Engineering, Nanchang Hangkong University, Nanchang, 330063, China

    Lipeng Deng, Pengliang Niu & Liming Ke

  2. School of Material Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Lipeng Deng & Jinhe Liu

  3. Canmet MATERIALS, Natural Resources Canada, 183 Longwood Road South, Hamilton, ON, L8P0A5, Canada

    Jidong Kang

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  1. Lipeng Deng
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  2. Pengliang Niu
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  3. Liming Ke
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  4. Jinhe Liu
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Correspondence to Lipeng Deng.

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The authors declare no competing interest.

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Deng, L., Niu, P., Ke, L. et al. Repairing of exit-hole in friction-stir-spot welded joints for 2024-T4 aluminum alloy by resistance welding. Int J Miner Metall Mater 30, 660–669 (2023). https://doi.org/10.1007/s12613-022-2561-x

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  • DOI: https://doi.org/10.1007/s12613-022-2561-x

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