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Refill friction stir spot welding (RFSSW): a review of processing, similar/dissimilar materials joining, mechanical properties and fracture mechanism

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Abstract

Refill friction stir spot welding (RFSSW) provides a novel method to join similar and/or dissimilar metallic materials without a key-hole in the center of the joint. Having the key-hole free characterization, the similar/dissimilar RFSSW joint exhibits remarkable and endurable characteristics, including high shear strength, long fatigue life, and strong corrosion resistance. In the meanwhile, as the key-hole free joint has different microstructures compared with conventional friction stir spot welding, thus the RFSSW joint shall possess different shear and fatigue fracture mechanisms, which needs further investigation. To explore the underlying failure mechanism, the similar/dissimilar metallic material joining parameters and pre-treatment, mechanical properties, as well as fracture mechanisms under this novel technology will be discussed. In details, the welding tool design, welding parameters setting, and the influence of processing on the lap shear and fatigue properties, as well as the corrosion resistance will be mainly discussed. Moreover, the roadmap of RFFSW is also discussed.

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Acknowledgements

This work was supported by International Science and Technology Cooperation Project of Guangdong Province (Grant No. 2022A0505050054), Innovation and Technology Fund (ITF) (Grant No. ITP/021/19AP), and National Natural Science Foundation of China (Grant No. 51905112).

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Authors and Affiliations

  1. Guangdong Provincial Key Laboratory of Advanced Welding Technology, China-Ukraine Institute of Welding, Guangdong Academy of Sciences, Guangzhou, 510000, Guangdong, China

    Yun-qiang Zhao & Aloshyn Andriia

  2. Smart Manufacturing Division, Hong Kong Productivity Council, Hong Kong, 999077, China

    Hao-kun Yang, Hong-hang Lo & Jia-xin Li

  3. E.O.Paton Electric Welding Institute of National Academy of Sciences of Ukraine, Kiev, 01001, Kievan, Ukraine

    Aloshyn Andriia

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  1. Yun-qiang Zhao
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Correspondence to Hao-kun Yang.

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Zhao, Yq., Yang, Hk., Andriia, A. et al. Refill friction stir spot welding (RFSSW): a review of processing, similar/dissimilar materials joining, mechanical properties and fracture mechanism. J. Iron Steel Res. Int. (2024). https://doi.org/10.1007/s42243-024-01209-2

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