Effect of pin geometry, rotational speed, and dwell time of tool in dissimilar joints of low-carbon galvanized steel and aluminum 6061-T6 by friction stir spot welding

Abstract

In this study, aluminum 6061-T6 plates were joined with low-carbon galvanized steel using friction stir spot welding. Three conical pins with varying lengths (short, medium, and long) were utilized, along with different dwell times and rotation speeds of the tool. The objective of this research was to compare the simultaneous effects of several important process parameters on mechanical and welding properties. The results indicate that the use of short conical pins significantly increased the microhardness in the upper aluminum plate. Conversely, increasing the pin length led to higher microhardness in the lower steel plate. Tensile shear loading was greater for short pins compared to medium pins, attributed to the influence of the tool shoulder. However, with increasing pin length, failure loading reached its highest value due to the dispersion of particles in the weld. The failure mode for short pins exhibited a mixed pattern, which transitioned to a ductile shape in all conditions as pin length increased. Overall, the most influential parameter was the tool penetration depth, which positively affected the obtained properties. The rotational speed of the tool was the second most significant parameter, followed by the dwell time.