Friction Stir Spot Welding

The friction stir welding process was developed in 1991 by The Welding Institute (TWI) for joining aluminum alloys (Thomas 1991) and subsequently the process has been used during joining of titanium, magnesium, zinc and copper alloys, and steel, in thicknesses ranging from 1 to 50 mm (Thomas, Threadgill, and Nicholas 1999; Nagasawa et al. 2000; Fukuda 2001; Cederqvist and Andrews 2004; Reynolds, Hood, and Tang 2005). The process involves plunging a rotating tool consisting of a cylindrical shoulder and protruding pin and traversing the tool across two pieces to be joined. Figure 8.1 shows a schematic of the friction stir welding process employed in producing a buttwelded section. It has been suggested that a combination of frictional heating, plastic deformation, and viscous dissipation produces temperatures in the stir zone that approach the solidus temperature. The stir zone region of aluminum alloy friction stir seam welds comprises a fine, equiaxed grain microstructure. A thermomechanically affected zone (TMAZ) formed adjacent to the stir zone contains elongated base metal grains and a partially recrystallized grain structure as a result of the thermal and stress/strain cycle, which is CoNTENTS

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