Abstract
Friction spot welding (FSpW) was applied to join the 7B04-T74 aluminum alloy successfully, and effects of sleeve plunge depth on weld appearance, microstructures and mechanical properties were investigated in detail. When the sleeve plunge depth was larger than 2mm, a surface indentation with a depth of 0.2mm should be applied in order to eliminate the defect of annular groove. The tensile shear properties of the joints were dependent on hook geometry, location of alclad layer, and hardness of stir zone (SZ). With increasing the sleeve plunge depth from 2 to 3.5mm, the hook height increased, the alclad layer downward migrated further and the hardness of SZ decreased. The optimized FSpW joint was obtained when the sleeve plunge depth was 3mm, and the corresponding tensile shear failure load was 11921N. Two different failure modes, i.e. shear fracture mode and tensile-shear mixed fracture mode, were observed in the tensile shear tests.
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