Influence of Adhesive in FSW: Investigation on Fatigue Behavior of Welded, Weld-Bonded, and Adhesive-Bonded Joints in Aluminum AA 6082 T6

Friction stir welding (FSW) is a solid-state technique, which has assumed an increasingly important role in automotive, naval, and aeronautical industry over the years. Nowadays, thanks to its several benefits, FSW is used to weld any type of metallic, polymeric, or composite material. In recent decades, adhesive bonding has also enhanced relevance due to a request for much lighter structures to increase performance without increasing fuel consumption. From a mechanical perspective, welding has a high tensile strength despite a low fatigue resistance through the lack of joint elasticity. Therefore, the aim of this study is to investigate and compare static and dynamic behavior of welded, weld-bonded, and adhesive-bonded joints. After choosing the most suitable adhesive, surface preparation, consisting of sandblasting, was carried out. First of all, on the basis of previous experience in FSW, the process parameters of hybrid welding were determined. Both quasi-static and dynamic behavior of welded, adhesive-bonded, and weld-bonded joints, made in overlapped configuration, were then compared. Experimental tests showed that the adhesive limits the negative effect, due to the presence of the structural notch of FSW overlapped joints.