Enhancing strength and metallurgical soundness of dissimilar Al-steel FSSW joints through novel exit hole refilling technique

Abstract

This study employed a novel technique of refilling exit hole in dissimilar Al-steel FSSW joints. Aluminum filler wire bits were utilized to replenish the metal for exit hole refilling. Refilling and restirring of the aluminum filler were performed using a pinless tool to compact the filled-up material. The resulting refilled joint was then examined to assess its metallurgical integrity and compared to a conventionally fabricated FSSW joint. The refilled metal exhibited strong adhesion to base metal plates and was free from cracks and voids. Furthermore, the joint strength achieved in this study surpassed the findings reported in contemporary research.