Experimental and Numerical Analysis of Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets

The refill friction stir spot welding (refill FSSW) process is a solid-state joining process to produce welds without a keyhole in spot joint configuration. This study presents a thermo-mechanical model of refill FSSW, validated on experimental thermal cycles for thin aluminium sheets of AA7075-T6....

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Bibliographic Details
Published in:Materials 2021-12, Vol.14 (23), p.7485
Main Authors: Janga, Venkata Somi Reddy, Awang, Mokhtar, Yamin, Mohd Fadillah, Suhuddin, Uceu F. H., Klusemann, Benjamin, Santos, Jorge F. dos
Format: Article
Language:English
Subjects:
Alloys
Aluminum base alloys
Friction stir welding
Mathematical models
Metal sheets
Numerical analysis
Numerical models
Refilling
Simulation
Spot welding
Stress concentration
Temperature effects
Thermocouples
Three dimensional flow
Three dimensional models
Velocity
Welded joints
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Summary:The refill friction stir spot welding (refill FSSW) process is a solid-state joining process to produce welds without a keyhole in spot joint configuration. This study presents a thermo-mechanical model of refill FSSW, validated on experimental thermal cycles for thin aluminium sheets of AA7075-T6. The temperatures in the weld centre and outside the welding zone at selected points were recorded using K-type thermocouples for more accurate validation of the thermo-mechanical model. A thermo-mechanical three-dimensional refill FSSW model was built using DEFORM-3D. The temperature results from the refill FSSW numerical model are in good agreement with the experimental results. Three-dimensional material flow during plunging and refilling stages is analysed in detail and compared to experimental microstructure and hardness results. The simulation results obtained from the refill FSSW model correspond well with the experimental results. The developed 3D numerical model is able to predict the thermal cycles, material flow, strain, and strain rates which are key factors for the identification and characterization of zones as well for determining joint quality.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma14237485