Abstract
A pinless tool design was proposed to achieve high butt tensile strength in aluminum alloy sheets (∼3mm thick) in friction stir welding (FSW), where a 7mm long cylindrical insert rod made of aluminum alloy was tightly embedded into a hollow cylindrical tool. The effects of rod diameter (d) on the welding properties and mechanism of weld formation were investigated. For friction stir spot welding (FSSW), the maximum rate of temperature rise was about 12.8°C/s, and the failure load was about 2kN for this pinless tool (d=10mm), with these being about 7.4°C/s and 1.35kN for the plain one. For FSW, the failure load was about 1.46kN for this tool, and about 0.72kN for the plain one. The abutting edges of sheets with a thickness of 3mm could be welded using this pinless tool.
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