Abstract
Friction stir spot welding-FSSW has been suggested as effectual process to welding difficult materials such as dissimilar materials and thin sheet of metal alloys. In this study, using dissimilar materials were welded carbon steel-1006 on upper plate and aluminum alloy AA2024-T3 on lower plate. Macrostructure, micro-structural analysis and mechanical properties of the joints are done. The effect of penetration depth, dwell time and spindle speed on tensile shear load are investigated with invariable of other parameter during welding process. The maximum tensile shear load (3.31KN) was occurred when using 0.4mm of penetration depth, 10 sec of dwell time and 1400 rpm of spindle speed. Also, two type of failure shape was observed interfacial fracture of carbon steel sheet and pull-out fracture of AA2024-T3 sheet.
Highlights
The direction of automotive industries is to raise the use of lightweight material instead of conventional steel, but aluminum is cost and addition aluminum is lower mechanical properties than steel
FSSW is a solid state joining method, the part or sample doesn't melt during welding, this method is a very important and novel variant of the linear friction stir welding (FSW) [5,6] Friction stir spot welding (FSSW) is a very important and novel variant of the linear friction stir welding (FSW,)which gives higher potential to be a replacement of single point joining processes such as riveting and resistance spot welding
A according the results below, the value of tensile shear load depending on many variables such as penetration depth, spindle speed and dwell time
Summary
The direction of automotive industries is to raise the use of lightweight material instead of conventional steel, but aluminum is cost and addition aluminum is lower mechanical properties than steel. T. Liyanage et al in (2014) investigated spot joining between AA6111 / low carbon steel sheets by using pin penetration depth of 0.4 mm, plunge rate of 1 mm /sec and tool rotational speed of 3000 r.p.m. AA6111with low carbon steel dissimilar joints friction spot welding overcame the failure strength properties needed resistance friction stir spot welding of aluminum alloy as base material, the intermetallic phases and the finding many of cracks lead to impact toughness properties and poor ductility [13]. E .Taban et al in (2009) joined between Al alloy (6061-T6) and steel (AISI 1018) by using friction spot welding with many parameters and this welding evaluated by metallurgical analysis such as micro-structural and (SEM) scanning electron microscopy, mechanical testing such as micro-hardness Results of these tests provide the failures were seen on the aluminum side in the plasticized layer of the joint. After that estimate the optimum condition for friction stir spot welding process
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