Abstract
In this present study, the two independent tools were used in the RFSSW process to joint similar material of AA1100 with a thickness of 0.42 mm using lap joint configuration. Effect of tools geometry and dwell time on mechanical properties, and macrograph was investigated. The joints were successfully obtained with better surface appearance. The micro-hardness variation at 4 group location shows higher than the base metal, while the maximum micro-hardness was obtained at parameter TC-8 at the center of the weld. Macrograph analysis showed the important factor that brings the plug fracture in all combination of parameters. It was the upward bending hook that leads to the crack propagate along the stirred zone to the top sheet, resulted in tear-off the top sheet from the bounded region. Increasing dwell time and tools size will increase the maximum tensile shear load significantly. The best average value of maximum tensile shear load that has been achieved was 561±24 N using the parameter tool C with 8 s dwell time (TC-8).
Highlights
Friction stir welding (FSW) is widely and very popular for joining aluminum alloys and has many advantages from other conventional welding processes such as resistance spot welding (RSW) or fusion welding such as TIG/MIG [1]
During the friction stir spot welding (FSSW) process, the plasticized material pushed into the gap between the top and bottom sheets, this creates distortion and space that called upward bulging
This could happen when there was a lack of shoulder indentation and small shoulder size to press, consequence in lack of restraint the material flow into the overlapped sheets
Summary
Friction stir welding (FSW) is widely and very popular for joining aluminum alloys and has many advantages from other conventional welding processes such as resistance spot welding (RSW) or fusion welding such as TIG/MIG [1]. Friction stir welding was invented by the TWI in 1991 It can be implemented such in aluminum, copper, magnesium, titanium, zinc, even steel [2],[3]. FSW has derived another technique namely friction stir spot welding (FSSW). The process that involving FSSW almost the same as FSW, but only at one spot during the process. A technique called refill friction stir spot weld introduced and developed by GKSS GmbH [4] in 2004. Many researchers used one compact tool that involves those two stages [4]-[10]. While the other uses two independent tools [11]
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