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research-article

ELECTRICALLY ASSISTED FRICTION STIR SPOT WELDING OF ALUMINUM ALLOY TO ADVANCED HIGH STRENGTH STEEL

[+] Author and Article Information
Kai Chen

University of Michigan, Ann Arbor, MI, 48105
chenkai@umich.edu

Xun Liu

University of Michigan, Ann Arbor, MI, 48105
xunxliu@umich.edu

Jun Ni

University of Michigan, Ann Arbor, MI, 48105
junni@umich.edu

1Corresponding author.

ASME doi:10.1115/1.4038993 History: Received March 20, 2017; Revised November 20, 2017

Abstract

A hybrid friction stir resistance spot welding process is applied for joining aluminum alloy 6061 to TRIP 780 steel. Compared with conventional resistance spot welding, the applied current density is lower and the welding process remains in the solid state. Compared with conventional friction stir spot welding (FSSW) process, the welding force is reduced and the dissimilar material joint strength is increased. The electrical current is applied in both a pulsed and direct form. With the equal amount of energy input, the approximately same force reduction indicates that the electro-plastic material softening effect is insignificant during FSSW process. The welding force is reduced mainly due to the resistance heating induced thermal softening of materials. With the application of electrical current, a wider aluminum flow pattern is observed in the thermo-mechanically affected zone of weld cross sections and a more uniform hook is formed at the Fe/Al interface. This implies that the aluminum material flow is enhanced. Moreover, the Al composition in the Al-Fe interfacial layer is higher, which means the atomic diffusion is accelerated

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