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Updated: Sep 13, 2025

Generating Lap Joints Via Friction Stir Spot Welding on DP780 Steel
Published on: August 13, 2019
Tool Geometries and Design of Friction Stir Spot Welding (FSSW) Tools and Effect on Weld Properties-A Comprehensive
Aravinthan Arumugam1, Animesh Kumar Basak2, Alokesh Pramanik3
1School of Mechanical Engineering, Engineering Institute of Technology, Perth, WA 6005, Australia.
Abstract:
The incorporation of multi-material design (MMD) to achieve lightweight vehicles requires Friction Stir Spot Welding (FSSW) to join steel with aluminum, magnesium, or composites. This study investigates the mechanisms, challenges, and performance of FSSW in MMD based on the information available in the literature. It also explores the effect of FSSW tool geometries and design on the spot weld formation and mechanical strength. Larger shoulder and pin diameters increase heat generation during welding. A concave shoulder profile produces a stronger weld compared to flat and convex profiles due to its ability to trap materials and transfer materials to the sheet interface efficiently for the development of a sound weld. Grooves such as Fibonacci and involute, and threads on P-FSSW and R-FSSW tools, also contribute to effective material flow during welding, hence assisting in heat generation. This review also provides recommendations on tool design for FSSW, P-FSSW, and R-FSSW.
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