Abstract
As the main factor significantly influencing the material flow behavior during friction stir spot welding (FSSW), tool geometry plays an important role on the weld quality. In this study, a tool with a half-threaded pin aiming to enhance the material flow at the lap interface but induces lower heat input was successfully put forward and manufactured. Using alclad 2A12-T4 aluminum alloy as the research object, the FSSW processes using tools with half-threaded pin and full-threaded pin were investigated by experimental and simulation methods. Compared with the full-threaded pin, peak temperature during welding using the half-threaded pin is lower than that using the full-threaded pin. The half-threaded pin was beneficial for attaining bigger bonding width at the lap interface, which resulted from the higher material flow velocity. Cross tension failure load of the welds using the half-threaded pin is bigger than that using the full-threaded pin, which agrees with the different bonding widths. Fracture morphologies directly prove bigger bonding width on the weld using the half-threaded pin.
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