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Materials 2016, 9(8), 677; doi:10.3390/ma9080677

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach

Advanced Institute for Manufacturing with High-Tech Innovations & Mechanical Engineering, National Chung-Cheng University, Chia-Yi 621, Taiwan
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Academic Editor: Jonathan Phillips
Received: 28 June 2016 / Revised: 2 August 2016 / Accepted: 5 August 2016 / Published: 9 August 2016
(This article belongs to the Section Manufacturing Processes and Systems)
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Abstract

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design. View Full-Text
Keywords: tool design; thermal-mechanical model; friction stir spot welding; spot friction welding; lap-shear specimen tool design; thermal-mechanical model; friction stir spot welding; spot friction welding; lap-shear specimen
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Su, Z.-M.; Qiu, Q.-H.; Lin, P.-C. Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach. Materials 2016, 9, 677.

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