Abstract
ABSTRACTDefect-free joints were produced in 2.0 mm thick 7075-T6 Al alloy by refill friction stir spot welding using a modified tool. Weld performance was evaluated in terms of microstructure, interfacial bonding, hardness, static and fatigue strength based on the experimental observations. The results indicated that grain size, interfacial bonding quality and lap shear strength significantly depend on sleeve penetration depth (SPD), with sufficient interfacial bonding and stable lap shear strength achieved when SPD ≥ 1.8 mm. The SPD and applied load played a dominant role in determining the static lap shear and fatigue failure mechanisms, respectively. More precisely, the lap shear failure mode was an interfacial failure when SPD ≤ 1.8 mm, and nugget pullout when SPD ≥ 2.0 mm. The fatigue fracture mode involved nugget pullout under high applied load, while fracture through the parent sheet occurs under medium and lower applied loads.
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