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Science and Technology of Welding and Joining Volume 24, 2019 - Issue 7
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Research Articles

Microstructure, static and fatigue properties of refill friction stir spot welded 7075-T6 aluminium alloy using a modified tool

Z. ShenSchool of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, People’s Republic of China;Shanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, People’s Republic of China;State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, People’s Republic of China;Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, CanadaCorrespondence[email protected]
[email protected]
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Y. DingDepartment of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, CanadaView further author information
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J. ChenCanmetMATERIALS, Natural Resources Canada, Hamilton, CanadaView further author information
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L. FuSchool of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, People’s Republic of China;Shanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, People’s Republic of China;State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, People’s Republic of ChinaView further author information
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X. C. LiuSchool of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, People’s Republic of China;Shanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, People’s Republic of China;State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, People’s Republic of ChinaORCID Iconhttps://orcid.org/0000-0002-0313-6697View further author information
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H. ChenSchool of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, People’s Republic of China;Shanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, People’s Republic of China;State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, People’s Republic of ChinaView further author information
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W. GuoSchool of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, People’s Republic of China;Shanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, People’s Republic of China;State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, People’s Republic of ChinaView further author information
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A. P. GerlichDepartment of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, CanadaORCID Iconhttps://orcid.org/0000-0003-0270-7475View further author information
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Pages 587-600 | Received 06 Dec 2018, Accepted 30 Dec 2018, Published online: 31 Jan 2019
 
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ABSTRACT

Defect-free joints were produced in 2.0 mm thick 7075-T6 Al alloy by refill friction stir spot welding using a modified tool. Weld performance was evaluated in terms of microstructure, interfacial bonding, hardness, static and fatigue strength based on the experimental observations. The results indicated that grain size, interfacial bonding quality and lap shear strength significantly depend on sleeve penetration depth (SPD), with sufficient interfacial bonding and stable lap shear strength achieved when SPD ≥ 1.8 mm. The SPD and applied load played a dominant role in determining the static lap shear and fatigue failure mechanisms, respectively. More precisely, the lap shear failure mode was an interfacial failure when SPD ≤ 1.8 mm, and nugget pullout when SPD ≥ 2.0 mm. The fatigue fracture mode involved nugget pullout under high applied load, while fracture through the parent sheet occurs under medium and lower applied loads.

Acknowledgements

The assistance with language correction from Wei Qiao in Vitasoy Australia Products is greatly acknowledged.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

This work has been supported by the Natural Science and Engineering Council (NSERC) of Canada, the Canadian Foundation for Innovation. Financial support from Ford Motor Co. is also greatly appreciated.

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