Abstract
The high-strength aluminum alloys offer great potential for realizing lightweight constructions in car body construction. However, the use of aluminum alloys increases the overall thickness of the material, which poses new challenges for potential joining processes. This paper examines a process combination of friction stir spot welding (FSSW) and bonding for 4 mm EN AW 6082-T6 sheets. For the investigations, adhesive or glass beads were applied between the joining components and then the sheets were welded using FSSW. The analysis shows that the adhesive and the glass beads have a very small influence on the joint formation. The use of glass beads in FSSW with bonding is recommended because less adhesive is displaced from the joint area, which increases the joint strength. The target of obtaining high weld spot strengths without strength-reducing adhesive burn-off could not be achieved because a certain residence time is necessary to form a weld spot with high strength at this sheet thickness in order to sufficiently plasticize the material. Adhesive burn-up cannot be completely avoided. For this reason, it is necessary to weigh up which characteristics are required for the specific application and adjust the welding parameters accordingly.
Highlights
Friction stir welding with adhesive bonding (FSSBW) is a hybrid joining process consisting of friction stir spot welding (FSSW) and adhesive bonding
Friction stir welding with adhesive bonding (FSSBW) is a hybrid joining process consisting of FSSW and adhesive bonding
The optimum speed for the FSSW tests has already been worked out, which is used in the FSSBW
Summary
Friction stir welding with adhesive bonding (FSSBW) is a hybrid joining process consisting of FSSW and adhesive bonding. Combinations of bonding and a (mechanical) spot joining process are frequently used, whereby the spot joining process serves to fix the joining partner during adhesive curing These process combinations result in increased strength, stiffness, and vibration resistance of the sheet metal joint. In the case of clinching thick sheet metals, the high forces required have a negative effect, which can lead to uncontrolled bending (component distortion) of the sheet metal pairs, promoting gap formation and inadequate seam sealing. The latter increasing the risk of corrosion cracking [6]
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