Skip to main content
Log in

Increasing the Fatigue Life of Dissimilar Friction Stir Spot Welded Al/Cu Joints by Optimization of Technological Parameters

  • Published:
Journal of Applied Mechanics and Technical Physics Aims and scope

Abstract

Friction stir spot welding is a new technique used in industries for spot joining dissimilar combinations. In this investigation, dissimilar combinations of Al5052 aluminium and C10100 copper are joined by using this technique with variations of important process parameters, such as the tool rotational speed, dwell duration, and plunging depth. A central composite design model is developed for establishing empirical relationships between the process parameters and the fatigue life of the joints (number of cycles to fracture). The analysis of variance is used for determining the significance of the developed model. The response surface methodology is used for maximizing the fatigue strength. By confirmation experiments, the model is validated, and the error is found to be within four percent.

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

Access this article

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

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. W. M. Thomas, E. D. Nicholas, J. C. Needham, et al. “Friction Welding,” US Patent No. 5460317 (Welding Inst., London, 1995).

    Google Scholar 

  2. K. Matsugi, Y. Wang, T. Hatayama, et al., “Application of Electric Discharge Process in Joining Aluminum and Stainless Steel Sheets,” J. Materials Proc. Technol. 135, 75–82 (2003).

    Article  Google Scholar 

  3. H. Badarinarayan, Fundamentals of Friction Stir Spot Welding, Ph.D. Thesis (Missouri Univ., S. l., 2009).

    Google Scholar 

  4. Y. Uematsu, K. Tokaji, Y. Tozaki, and Y. Nakashima, “Fatigue Behaviour of Dissimilar Friction Stir Spot Weld between A6061 and SPCC Welded by a Scrolled Groove Shoulder Tool,” Procedia Eng. 2, 193–201 (2010).

    Article  Google Scholar 

  5. A. M. Malafaia, M. T. Milan, M. F. Oliveira, and D. Spinelli, “Fatigue Behavior of Friction Stir Spot Welding and Riveted Joints in an Al Alloy,” Procedia Eng. 2, 1815–1821 (2010).

    Article  Google Scholar 

  6. Y. Uematsu, K. Tokaji, S. Murata, et al., “Fatigue Behaviour of Friction Stir Spot Welded Al–Mg–Si Alloy,” J. Soc. Materials Sci. 56 (6), 537–543 (2007).

    Article  Google Scholar 

  7. D. A. Wang and C. H. Chen, “Fatigue Lives of Friction Stir Spot Welds in Aluminum 6061-T6 Sheets,” J. Materials Proc. Technol. 209 (1), 367–375 (2009).

    Article  MathSciNet  Google Scholar 

  8. B. Wang, Q. Q. Duan, G. Yao, et al., “Fatigue Fracture Behaviour of Spot Welded B1500HS Steel under Tensile Shear Load,” Fatigue Frac. Eng. Mat. Struct. 1 (1), 1–8 (2015).

    Google Scholar 

  9. V. Balasubramanian, M. Joseph Fernandus, and T. Senthilkumar, “Development of Processing Windows for Diffusion Bonding of Aluminium/Magnesium Dissimilar Materials,” Weld World 57, 526–539 (2013).

    Article  Google Scholar 

  10. J. Grum and J. M. Slabe, “The Use of Factorial Design and Response Surface Methodology for Fast Determination of Optimal Heat Treatment Conditions of Different Ni–Co–Mo Surfaced Layers,” J. Materials Proc. Tech. 155, 2026–2032 (2004).

    Article  Google Scholar 

  11. A. K. Lakshminarayanan, V. E. Annamalai, and K. Elangovan, “Identification of Optimum Friction Stir Spot Welding Process Parameters Controlling the Properties of Low Carbon Automotive Steel Joints,” J. Mater. Res. Technol. 4 (3), 262–272 (2015).

    Article  Google Scholar 

  12. D. C. Montgomery, Design and Analysis of Experiments (John Wiley and Sons, New York, 2001).

    Google Scholar 

  13. R. Paventhan, P. R. Lakshminarayanan, and V. Balasubramanian, “Prediction and Optimization of Friction Welding Parameters for Joining Aluminium Alloy and Stainless Steel,” Trans. Nonferrous Metals Soc. China 21, 1480–1485 (2011).

    Article  Google Scholar 

  14. J. E. F. Miller and R. Johnson Probability and Statistics for Engineers (Prentice Hall, New Delhi, 1996).

    MATH  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to S. Siddharth.

Additional information

Original Russian Text © S. Siddharth, T. Senthilkumar.

Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 59, No. 2, pp. 160–166, March–April, 2018.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Siddharth, S., Senthilkumar, T. Increasing the Fatigue Life of Dissimilar Friction Stir Spot Welded Al/Cu Joints by Optimization of Technological Parameters. J Appl Mech Tech Phy 59, 326–331 (2018). https://doi.org/10.1134/S0021894418020165

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1134/S0021894418020165

Keywords

Navigation