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Updated: Aug 19, 2025

Generating Lap Joints Via Friction Stir Spot Welding on DP780 Steel
Published on: August 13, 2019
Modeling of Probeless Friction Stir Spot Welding of AA2024/AISI304 Steel Lap Joint
Mariia Rashkovets1, Nicola Contuzzi1, Giuseppe Casalino1
1Dipartimento di Meccanica, Matematica e Management, Polytechnic University of Bari, Via Orabona 4, 70125 Bari, Italy.
Abstract:
In the present study, AA2024 aluminum alloy and AISI304 stainless steel were welded in a lap joint configuration by Probeless Friction Stir Spot Welding (P-FSSW) with a flat surface tool. A full factorial DOE plan was performed. The effect of the tool force (4900, 7350 N) and rotational speed (500, 1000, 1500, 2000 RPM) was analyzed regarding the microstructure and microhardness study. A two-dimensional arbitrary Eulerian-Lagrangian FEM model was used to clarify the temperature distribution and material flow within the welds. The experimental results for the weld microstructures were used to validate the temperature field of the numerical model. The results showed that the tool rotation speed had an extensive influence on the heat generation, whereas the load force mainly acted on the material flow.
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