Abstract
Friction stir spot welding (FSSW) is one of the effective solid-state welding strategies to achieve good joint efficiency between dissimilar aluminum alloys. However, the formation of tool-induced keyhole (a stress raiser) is inevitable during the FSSW process. This study explores the possibility of eliminating keyhole with the aim of improving the properties of the joint by Modified Friction Stir Clinching (MFSC) process. The tensile-shear and cross-tension strengths of the MFSC joints are 83% and 50% higher than that of the specimens joined by FSSW. The article presents a comprehensive analysis of the material flow characteristics, microstructural evolution, and tensile properties of the dissimilar joints between AA2024-T3 and AA6061-T6 that was enabled by the MFSC process.
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