Abstract
This investigation is performed to compare the resistance spot welding (RSW) of aluminum alloy (2024-T3) with friction stir spot welding (FSSW) techniques. In this work, parameters of both resistance spot welding (RSW) and friction stir spot welding (FSSW) techniques were optimized and the optimum welding variables for both techniques were obtained. For FSSW, the tensile shear strength increased with increasing probe length, tool rotational speed and tool holding time. Tensile shear force value of RSW is about 66% of that of FSSW. This is explained by the coarse dendritic structure in resistance spot welding compared to the plastically deformed stir zone and heat affected zone in FSSW. The ratio of nugget shear strength of RSW and FSSW to base metal is about 71% and 149% respectively. The maximum hardness was obtained in stir zone at the surface of the tool. Very fine grain size of about 4 microns was obtained in stir zone followed by elongated and rotated grains in TMAZ where dynamic recrystallization did not occur.
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