Abstract
Recently, friction stir welding of dissimilar materials has emerged as one of the most significant issues in lightweight, eco-friendly bonding technology. In this study, we welded the torsion beam shaft—an automobile chassis component—with cast aluminum to lighten it. The study rapidly and economically investigated the effects of friction stir welding and process parameters for A357 cast aluminum and FB590 high-strength steel; 14 decomposition experiments were conducted using a definitive screening design that could simultaneously determine the effects of multiple factors. Friction stir welding experiments were conducted using an optical microscope to investigate the tensile shear load behavior in the welding zone. In addition to understanding the interactions between tool penetration depth and plunge speed and tool penetration depth and dwell time, we investigated and found that tool penetration depth positively affected the size of the hooking area and contributed to the stabilization and size reduction of the cavity. The experimental results showed that the plunge depth and tool penetration depth effects were most important; in this case, the plunge depth negatively affected the magnitude of tensile shear load, whereas the tool penetration depth had a positive effect. Therefore, when selecting a tool, it is important to consider the plunge depth and tool penetration depth in lap welding.
Highlights
Published: 3 October 2021Recently, environmental protection and energy-saving strategies—including weight reduction and miniaturization—have emerged as critical issues in the automobile and other industries [1,2,3]
Among the process variables that have an important influence—other than tools—six factors were selected as the factors affecting the tensile shear load (TSL) of dissimilar materials for FSLW, including those not selected by the previous researchers in the experimental plan
The tool rotational speed, tool welding speed, plunge speed, dwell time, plunge depth, and tool penetration depth were selected among the process variables; and the response was studied through the TSL values
Summary
Environmental protection and energy-saving strategies—including weight reduction and miniaturization—have emerged as critical issues in the automobile and other industries [1,2,3]. To reduce defects and increase the mechanical strength of these FSW joints, many researchers have conducted studies on tool shape and process parameters [10,11,12,13,14,15,16,17,18,19]. Choy et al [37] reported the effect of each process factor on tensile shear load (TSL) by performing FSW based on the DSD experimental design for five process factors with three levels for the lap joint of each 3 mm thick pipe-shaped A357 cast Al and FB590 high-strength steel, using a tool of a single dimension. 3 (depth of plunge was level 2 [51])
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