Comparison of Resistance Spot Welding and Refill Friction Stir Welding of Al 7075 Sheets. Jeff Hou

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1 Comparison of Resistance Spot Welding and Refill Friction Stir Welding of Al 7075 Sheets Jeff Hou Z.Shen, Y. Chen, N. Zhou, M. Worswick, A. Gerlich, K. Chan, N. Scotchmer 1

2 Friction Stir Welding (FSW) Background: Retreating Side Advancing Side - Proven process for commercial welding of Al, Mg, Steel, and Ti alloys onion ring structure in stir zone Fine grains with good mechanical properties 2

3 Background Conventional Friction stir spot welding Typical parameters: RPM rotation speed mm/s plunge rate 1 5 s cycle times 3

4 Conventional friction stir spot weld 2004 Mazda RX Toyota Prius - Significantly reduced energy consumption and capital 4

5 Typical Friction Stir Spot Weld Microstructure Stir zone TMAZ HAZ Sheet interface Weld microstructures consist of three main regions: Stir Zone: Fine, equiaxed grains <10 µm TMAZ: HAZ: Thermo-mechanically affected zone: elongated grain structure Coarsening of precipitates resulting in reduced strength

6 Typical Friction Stir Spot Weld Strengths In general, the fracture loads are directly proportional to the bonded area and the energy applied during weld formation. All of the energy serves to stir the material around the pin, which softens and forms the ring of bonded material between the sheets. Su, P., Gerlich, A., North, T. H., and Bendzsak, G. J., SAE Technical Series: , 2006

7 Typical RFSS Weld Microstructure Pure Al cladding layer Optical micrograph showing the microstructure of a refill friction stir spot weld made in Alclad 2024 alloy sheet Since the keyhole indentation is absent, a greater bonded area is produced, however the welding times are typically slightly higher. Tier, M. D., dos Santos, J., Rosendo, T., Mazzaferro, J. A., and da Silva, A. A. M., SAE Technical Series: ,

8 Typical RFSS Weld Strengths 1.7 mm-thick AA6181-T4 aluminium alloy. AA6181-T4 and 2024-T3 Alclad joints have been studied Generally higher for the same base material joints compared to conventional Friction stir spot welding, however properties increase with weld times ~ 3s T. Rosendo et al. / Materials and Design 32 (2011)

9 Refill Friction Stir Spot Welding Equipment Machine Capacity Spindle speed of 3000 rpm, 2.2 kw Plunging speeds of up to 3.6 mm/s Maximum force 11kN 9

10 Al 7075 Base Material Thickness: 0.8 mm Size: 100mm x 25mm Welding Parameters Studied: Tool rotation speed: 2100 RPM Plunge Depth: 0.85, 0.95 and 1.10 mm Welding Time: 3 and 3.5 sec Tool design: 6 mm pin, 9 mm shoulder OD AL-7075-T6: No pre-cleaning or surface treatment done 10

11 Refill Al 7075 Spot Weld Microstructures Plunge depth / Welding Time Recrystallized volume increases with time and plunge depth Fine hook region near periphery of weld caused by material flow 11

12 Refill Al 7075 Spot Weld Hook Features Plunge depth / Welding Time Hooks are stress concentration regions that are generally detrimental to weld fracture load. faying interface The height of the hook increases with welding time and plunge depth However, the unbonded faying interface ends outside of the hook 12

13 Refill Al 7075 Weld Overlap Shear Testing Mainly nugget pull-out AWS Minimum requirement is 3.02 kn for this sheet material 13

14 Refill Al 7075 Spot Weld Microhardness Microhardness distribution indicates full dissolution within stir zone followed by natural aging Hardness distributions are similar, however increasing plunge depth produces wider HAZ 14

15 RFSSW Summary Based on the AWS D8.1M:2007 standard, the tensile shear strength for 0.8 mm thick Al 7075 sheet (3.02 kn) can be readily achieved using Refill Friction Stir Spot Welding Joint Strengths increase with time or plunge depth 15

16 Resistance spot welding of Al7075-T6 Fusion welding of Al 7075 alloy is problematic. Only preferred fusion welding => RSW Equipment Used 144/180 kva MFDC Welder 60kA Current & 25kN Force Electrode RWMA Female F Style Class II 2 Inch Radius 16

17 RSW Parameters for Al 7075 Initial Trial Weld Current [ka] Weld Time [Cycles] Failure Mode Observations 5 N/A No Bond 10 Small Bond Int Bond achieved with slight expulsion in faying region Plug Electrode sticking and heavy expulsion in faying region 30 Worse electrode sticking, large faying region expulsion, bond No surface treatment were done to the Al 7075 T6 sheets 17

18 RSW Al 7075 Weld Tensile Shear Strength Max Force VS Weld Single Pulse For Untreated Al 7075 T6 Max Tensile Force (kn) AWS Minimum Tensile Force Welding Current (ka) Strength values significantly drop when using as received sheets (without etching) 18

19 RSW Parameters for Al 7075 Second Trial Weld Current [ka] Weld Time [Cycles] Failure Mode Observations All Plug No nugget expulsion but increasing electrode sticking as current increases. Similar to above with increasing sticking and faying gap. Weld nugget surface cracking begin to show 40 Full Electrode Stick (Bottom Electrode) and surface crack The Al coupons were ultrasonically cleaned in ethanol for 10 minutes and treated with solution of 1.2 ml HF, 67.5 ml HNO 3 and 100 ml water for 40 seconds 19

20 RSW Al 7075 Weld Tensile Shear Strength Max Force VS Weld cyc Multi Pulse For Etched AL7075 T6 5 Max Tensile Force (kn) AWS Minimum Tensile Force Welding Current (ka) The Al coupons were ultrasonically cleaned in ethanol for 10 minutes and treated with solution of 1.2 ml HF, 67.5 ml HNO 3 and 100 ml water for 40 seconds 20

21 RSW Al 7075 Weld Microstructures Cross section when using welding current 30kA 21

22 RSW Al 7075 Weld Microstructures Cross section when using welding current 40kA Partially melted region at top of Nugget 22

23 RSW Al 7075 Weld Micro-hardness 30ka 23

24 RSW of Al7075-T6 Summary RSW of the Al 7075 material requires surface cleaning pre treatment to achieve minimum required TSS 24

25 Thank you Acknowledgements: Questions? 25

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