Abstract
Nowadays, the replacement of steel with lightweight materials such as aluminum causes an increased demand for joining of dissimilar materials in the automotive and aerospace industries. Dissimilar joining of components with Adhesive Bonding (AB) is a widely used method that distributes the load over a greater area than mechanical joints. However, peak stresses at the overlap edges results in premature failure. A solution to alleviate this problem is to implement a hybrid weld-bonded joint to reduce the stress concentration at the edges. In this study, the focus was to manufacture a hybrid weld-bonded joint where Friction-Stir-Spot-Welding (FSSW) was applied at the overlap edges. Tensile shear tests were performed to achieve the fracture load of various joint designs. The fracture surfaces were investigated, and numerical simulation was performed to achieve the fracture load of various joint designs. The fracture surfaces were investigated, and numerical simulation was performed to analyse the fracture mechanism and the interaction between adhesive bond and FSSW. In one of the test series, FSSW was applied in the overlap area near the edges of a similar lap-joint (Al–Al). Here, the adhesive bonding was burnt by the friction of the spinning tool and delaminated. Moreover, the material flow during FSSW was influenced by the presence of the adhesive bonding. To mitigate the interference between AB/FSSW, the spot weld was applied at the overlap edges. The results show that by bringing the FSSW closer to the edge, the bilateral detrimental interaction of AB and FSSW can be significantly reduced. However, the failure load of the hybrid bonded joint was still lower than the adhesive bonded one. Based on the results of the present study, FSSW and AB should be located as far as possible (at least for the selected adhesive) due to their completely different mechanisms of joining. The results can be informative for the development of new hybrid joining configurations with high performance.
Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
