Abstract
Sleeve friction stud welding (SFSW) was proposed to improve formation integrity and welding efficiency of stud joints. 18 mm diameter 5A06 stud and 15 mm thick 7A52 high-strength aluminum alloy were successfully joined at a time of 10 s. A uniform thickening joint with a chamfer was obtained, while flash defects in conventional welding were eliminated. The sleeve avoided the overflowing of plasticized materials, which facilitated material flow in the central of the joint corresponding to the taper stud, eliminating interfacial kissing-bond defects. The maximum tensile strength of SFSW joint reached 292 MPa, while fractured at the semi-hollow stud. SFSW has the potential to excellent joints with different sizes, offering a novel approach to advance of stud welding.
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