Title: Developing friction stir spot welding windows for dissimilar AL5083 and C10100 joints

Authors: S. Siddharth; T. Senthilkumar

Addresses: Department of Mechanical Engineering, University College of Engineering, Anna University, Tiruchirappalli – 620 024, India ' Department of Mechanical Engineering, University College of Engineering, Anna University, Tiruchirappalli – 620 024, India

Abstract: In this investigation, process operation limit diagrams in the form of friction stir spot welding windows for obtaining good quality friction stir spot joints were attempted using dissimilar combinations of aluminium Al 5083 and copper C10100. By varying the important process parameters such as tool rotational speed, plunge depth and dwell time, tool rotational speed-dwell time and tool rotational speed-plunge depth diagrams were constructed, considering the joint quality aspect, extent of flash formation, width and depth of keyhole, its tensile strength and interface hardness. Tensile properties of the joints were evaluated using lap shear tensile tests. Vickers micro hardness tester was used to evaluate interface hardness. Validation experiments proved that, the joints made by selecting process parameter values within the two windows, had higher strength and reduced interface hardness. These windows would act as reference maps for selection of appropriate parameters for strong joints.

Keywords: friction stir spot welding; FSSW; dissimilar joints; aluminium; copper; process operation limit diagrams; friction stir spot welding windows; FSSWW.

DOI: 10.1504/IJASMM.2017.088202

International Journal of Additive and Subtractive Materials Manufacturing, 2017 Vol.1 No.2, pp.145 - 160

Received: 02 Aug 2016
Accepted: 06 Feb 2017
Published online: 29 Nov 2017 *

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