This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Reducing Cycle Times of Refill Friction Stir Spot Welding in Automotive Aluminum Alloys
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on April 14, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
A major barrier, preventing RFSSW from use by manufacturers, is the long cycle time that has been historically associated with making a weld. In order for RFSSW to become a readily implementable welding solution, cycle times must be reduced to an acceptable level, similar to that of well developed, competing spot joining processes. In the present work, an investigation of the RFSSW process is conducted to evaluate factors that have traditionally prevented the process from achieving fast cycle times. Within this investigation, the relationship between cycle time and joint quality is explored, as is the meaning and measurement of cycle time in the RFSSW process. Claims and general sentiment found in prior literature are challenged regarding the potential for high-speed RFSSW joints to be made. The RFSSW weld design-as described by process parameters such as tool feed rate, tool rotational velocity, and plunge depth- is shown through experimentation to affect the loads and torques placed on RFSSW tooling and machines during the welding process. As cycle time is decreased, the load and torque on the toolset are shown to increase. Similarly, as tool rotational velocity is decreased, the load and torque on the toolset is shown to increase. The relationship between machine design limitations and cycle time is also explored. It is demonstrated that welds with cycle times below one second can be produced without compromising material properties, suggesting that high speed RFSSW can be enabled through informed efforts.
CitationLarsen, B. and Hovanski, Y., "Reducing Cycle Times of Refill Friction Stir Spot Welding in Automotive Aluminum Alloys," SAE Technical Paper 2020-01-0224, 2020.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
|[Unnamed Dataset 3]|
|[Unnamed Dataset 4]|
|[Unnamed Dataset 5]|
|[Unnamed Dataset 6]|
|[Unnamed Dataset 7]|
- Boldsaikhan, E. et al. , Refill Friction Stir Spot Joining for Aerospace Aluminum Alloys (Cham: Springer International Publishing, 2017).
- Rich, B. and Spodar, M. , “A Crazy, Mixed-Up Method of Welding,” Manufacturing Engineering 157(1):64-66, 2016.
- Schilling, C. and Santos, J.D. , “Method and Device for Joining at Least Two Adjoining Work Pieces by Friction Welding,” 2004.
- Parra, B. et al. , “An Investigation on Friction Spot Welding in Aa6181-T4 Alloy,” Tecnologia em Metalurgia e Materiais 8(3):184-190, 2011.
- Yang, H.G. and Yang, H.J. , “Experimental Investigation on Refill Friction Stir Spot Welding Process of Aluminum Alloys,” in 2013 3rd International Conference on Mechanical Engineering, Industry and Manufacturing Engineering, MEIME 2013, June 22-June 23, 2013, Trans Tech Publications Ltd., Wuhan, China.
- Kubit, A. et al. , “Failure Mechanisms of Refill Friction Stir Spot Welded 7075-T6 Aluminium Alloy Single-Lap Joints,” The International Journal of Advanced Manufacturing Technology 94(9-12):4479-4491, 2017.
- Xu, Z. et al. , “Refill Friction Stir Spot Welding of 5083-O Aluminum Alloy,” Journal of Materials Science & Technology 34(5):878-885, 2018.
- Zhao, Y.Q. et al. , “Effects of Sleeve Plunge Depth on Microstructures and Mechanical Properties of Friction Spot Welded Alclad 7B04-T74 Aluminum Alloy,” Materials & Design 62:40-46, 2014.
- “Material Property Data: Aluminum 5052-H36,” November 1, 2019; Available from: http://www.matweb.com/search/DataSheet.aspx?MatGUID=1a5729196f264cc78a3233bf558aee8a&ckck=1.
- Tier, M.D. et al. , “The Weld Interface for Friction Spot Welded 5052 Aluminium Alloy,” The International Journal of Advanced Manufacturing Technology 90(1-4):267-276, 2016.
- Reimann, M. et al. , “Refilling Termination Hole in AA 2198-T851 by Refill Friction Stir Spot Welding,” Journal of Materials Processing Technology 245:157-166, 2017.