Abstract
Protrusion friction spot stir welding (PFSSW) was introduced as a novel method to produce keyhole-free welds of a drawing quality special killed low carbon steel (DQSK). The effects of welding parameters such as tool rotation speed and plunging depth were investigated on the mechanical properties and metallurgical aspects. The sheet/sheet joint interface of the welds produced by PFSSW was visible and non-planar compared to the conventional FSSW method. Microstructure and hardness were affected by dynamic recrystallization and transformation hardening in the stir zone. Hardness value of the stir zone produced by the present work was much lower than that produced by resistance spot welding process due to martensite-free ferritic microstructure in the stir zone. Although all of the welds produced by the present work were failed in interface fracture mode, they exhibited the maximum load bearing capacity compared to other techniques.
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