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Generating Lap Joints Via Friction Stir Spot Welding on DP780 Steel
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Numerical and Experimental Analyses of Developed Friction Stir Spot Welding (DFSSW) Based on Systematic Design

Wassan S Abd Al-Sahb1, Suhair G Hussein1, M N Mohammed2

  • 1University of Baghdad College of Engineering Department of Mechanical Engineering, Baghdad, Iraq.

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|July 24, 2024
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Summary

A new Developed Friction Stir Spot Welding (DFSSW) technique for aluminum sheets significantly reduces keyhole defects. This optimized process achieved a high tensile shear force of 2388 N, proving its industrial viability.

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Joining Technologies

Background:

  • Traditional Friction Stir Spot Welding (FSSW) often results in keyhole defects.
  • Joining similar aluminum sheets (6061) requires robust and defect-minimized techniques.
  • Optimizing process parameters is crucial for enhancing weld quality and strength.

Purpose of the Study:

  • To develop and critically analyze an optimized Friction Stir Spot Welding (FSSW) technique for joining similar aluminum sheets.
  • To minimize or eliminate keyhole defects through parameter optimization in FSSW.
  • To validate the developed technique (DFSSW) using numerical simulation and experimental investigation.

Main Methods:

  • Numerical simulation using the finite element method to solve the thermomechanical coupling problem.
  • Analysis of temperature, stress distribution, and applied forces under varying parameters.
  • Experimental validation comparing tensile shear force results with traditional FSSW.

Main Results:

  • The developed FSSW technique (DFSSW) successfully joined 6061 aluminum sheets.
  • Optimal parameters (2100 rpm, 0.3 mm plunge depth, 3.5 mm height, 12 mm diameter) yielded a maximum tensile shear force of 2388 N.
  • Significant reduction in keyhole defects was observed compared to traditional FSSW.
  • Sliced disc diameter and height were identified as critical parameters for successful welding.

Conclusions:

  • The developed Friction Stir Spot Welding (DFSSW) technique effectively reduces keyhole defects in aluminum sheet joining.
  • Optimized design and working conditions are essential for achieving high joint strength and avoiding defects.
  • The developed technique shows promise for industrial applications due to its defect reduction and potential for automation.