The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminium alloys since the technique was invented in 1991 is reviewed The basic principles of FSW are described, including thermal history and metal flow, before discussing how process parameters affect the weld microstructure and the likelihood of entraining defects After introducing the characteristic macroscopic features, the microstructural development and related distribution of hardness are reviewed in some detail for the two classes of wrought aluminium alloy (non-heat-treatable and heat-treatable) Finally, the range of mechanical properties that can be achieved is discussed, including consideration of residual stress, fracture, fatigue and corrosion It is demonstrated that FSW of aluminium is becoming an increasingly mature technology with numerous commercial applications In spite of this, much remains to be learned about the process and opportunities for further research a

Friction stir welding of aluminium alloys

Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. Commercial feasibility of the FSW process for harder alloys such as steels and titanium alloys awaits the development of cost effective and durable tools which lead to structurally sound welds consistently. Material selection and design profoundly affect the performance of tools, weld quality and cost. Here we review and critically examine several important aspects of FSW tools such as tool material selection, geometry and load bearing ability, mechanisms of tool degradation and process economics.

Review: friction stir welding tools

Friction stir welding: Process, automation, and control

http://users.encs.concordia.ca/~tmg/images/c/ce/Cmq108.pdf

Review of tools for friction stir welding and processing

Spot welding, particularly resistance spot welding (RSW), is a critical joining process in automotive industry. The development of advanced high strength steels for applications in automotive industry is accompanied with a challenge to better understand the physical and mechanical metallurgy of these materials during RSW. The present paper critically reviews the fundamental understanding of structure–properties relationship in automotive steels resistance spot welds. The focus is on the metallurgical characteristics, hardness–microstructure correlation, interfacial to pullout failure mode transition and mechanical performance of steel resistance spot welds under quasi-static, fatigue and impact loading conditions. A brief review of friction stir spot welding, as an alternative to RSW, is also included.

Critical review of automotive steels spot welding: process, structure and properties

The effect of tool geometry on microstructure and static strength in friction stir spot welds of 6061 aluminium alloy sheets was studied. Tools with three different probe lengths were used to join the aluminium sheet with different tool rotational speeds and tool holding times. The weld microstructures varied significantly depending on probe length, tool rotational speed and tool holding time. Two particular aspects were identified: the thickness of the upper sheet under the shoulder indentation and the nugget size. The former decreased with increasing probe length at the shortest tool holding time and the slowest tool rotational speed, but there were no discernible differences in other welding conditions, while the latter increased with increasing probe length, tool rotational speed and tool holding time. The tensile shear strength increased with increasing probe length, while the cross-tension strength was not affected significantly by probe length. Two fracture modes were observed: shear fracture of the nugget and mixed mode fracture under tensile shear loading, and nugget debonding and pull-out under cross-tension loading. Based on experimental observation of the microstructures, the effect of probe length on static strength and the fracture mechanisms were discussed.

Effect of tool geometry on microstructure and static strength in friction stir spot welded aluminium alloys

A newly developed tool without probe for friction stir spot welding and its performance

Effect of re-filling probe hole on tensile failure and fatigue behaviour of friction stir spot welded joints in Al–Mg–Si alloy

Fatigue behaviour of friction stir welds without neither welding flash nor flaw in several aluminium alloys

The effect of processing parameters on static strength and fracture mechanisms of dissimilar friction stir spot welds between different aluminium alloys was studied. Tensile shear strength increased with decreasing tool rotational speed and increasing tool holding time, while cross tension strength decreased with increasing both parameters. Two fracture modes were observed: nugget shear fracture and mixed mode fracture under tensile shear loading, and debonding and pull-out of the nugget under cross tension loading. Based on experimental observation, the dependence of static strength on processing parameters and the occurrence of different fracture modes were discussed.

Yasunari Tozaki

Papers

Effect of tool geometry on microstructure and static strength in friction stir spot welded aluminium alloys

A newly developed tool without probe for friction stir spot welding and its performance

Effect of re-filling probe hole on tensile failure and fatigue behaviour of friction stir spot welded joints in Al–Mg–Si alloy

Fatigue behaviour of friction stir welds without neither welding flash nor flaw in several aluminium alloys

Effect of processing parameters on static strength of dissimilar friction stir spot welds between different aluminium alloys