Abstract
The goal of investigations included in this paper is to determine the effect of welding parameters on the load capacity of joints and an analysis of the defects in welded single-lap joints obtained by the refill friction stir spot welding method. Furthermore, a study is made of the effect of welding parameters on the tensile strength and fracture mode of joints subjected to tensile/pure shear loading. The overlapping friction stir spot welded joints are made of two 7075-T6 aluminium alloy sheets with different thicknesses (1.6 and 0.8 mm). The evaluation of joint quality was done using optical microscopy and scanning electron microscopy. The load capacity of joints is determined in tensile/pure shear loading tests. Microstructural analysis showed that the important parameters affecting the quality of the joints are the duration of welding and tool plunge depth. Depending on the tool plunge depth, three types of joint damage were observed. The test results indicate that incorrect selection of welding process parameters results in defects such as voids, hooks, onion rings and bonding ligament.
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