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Refill friction stir spot welding of aluminum alloys: State-of-the-art and Perspectives

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Abstract

Refill friction stir spot welding (RFSSW) is a solid-state spot joining method that has attracted more and more attention from academia and industry at present. RFSSW has been successfully and widely used to weld aluminum alloys, magnesium alloys and other materials. However, the flow behavior, microstructure and properties of aluminum alloy joints are not fully understood. Therefore, the relationships among welding processes, flow behavior, microstructure evolution, mechanical properties, corrosion and fatigue performance of RFSSW aluminum alloy joints are critically reviewed in this paper to provide a theoretical reference and data support for the industrial application of RFSSW. The first part analyzes the published articles on RFSSW joints indexed in the Web of Science database by using a bibliometric method. The second part briefly introduces the welding tools used in publications. The third part introduces the typical welding defects and microstructure evolution of RFSSW joints. The fourth part describes the mechanical properties and failure modes. The fifth part addresses the corrosion behavior and fatigue property of RFSSW joints. The sixth part briefly summarizes the potential applications of RFSSW technology. Finally, a summary of RFSSW joints and future studies are reported.

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Data Availability

The processed data required to reproduce these findings cannot be shared at this time as these data form part of an ongoing study.

Abbreviations

RFSSW:

Refill friction stir spot welding

RSW:

Resistance spot welding

FSSW:

Friction stir spot welding

FSW:

Friction stir welding

BM:

Base material

HAZ:

Heat-affected zone

TMAZ:

Thermo-mechanical affected zone

SZ:

Stir zone

SAZ:

Sleeve affected zone

PAZ:

Pin affected zone

SSZ:

Sleeve-SZ

PSZ:

Pin-SZ

HABs:

High angle boundaries

LABs:

Low angle boundaries

IPF:

Inverse pole figure

RD:

Rolling direction

TD:

Transverse direction

ND:

Normal direction

SAED:

Selected area electron diffraction

TSFL:

Tensile shear fracture load

IMC:

Intermetallic compound

SRP:

Suspension rotating process

PFZs:

Precipitate-free zones

FFP:

Friction molding process

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Acknowledgements

The authors gratefully acknowledge the financial support of the State Key Laboratory of Solidification Processing (NPU, China) (2021-TZ-01), the 2021 Doctoral Dissertation Innovation Fund Project (CX 2021067), the Research Fund of the State Key Laboratory of Solidification Processing (NPU, China) (2022-BJ-02), the National Natural Science Foundation of China (52105402), and the Natural Science Foundation of Shaanxi Province (2021-JQ-102).

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  1. State Key Laboratory of Solidification Processing, Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, PR, China

    Yangfan Zou, Wenya Li, Yu Su & Xiawei Yang

  2. College of Engineering and Technology, Southwest University, Chongqing, 400715, PR, China

    Zhikang Shen

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Zou, Y., Li, W., Shen, Z. et al. Refill friction stir spot welding of aluminum alloys: State-of-the-art and Perspectives. Weld World 67, 1853–1885 (2023). https://doi.org/10.1007/s40194-023-01552-0

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