Friction stir welding for the 21st century automotive industry
- Hinrichs J.F. ,
- Smith C.B. ,
- Orsini B.F. ,
- et al
- Hinrichs J.F. ,
- Smith C.B. ,
- Orsini B.F. ,
- DeGeorge R.J. ,
- Smale B.J. and
- Ruehl P.C.
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Description
Following an overview of friction stir spot welding (FSSW) for potential automotive applications (including robotic FSSW in poke welding and C-frame configurations, and pedestal FSSW machines for manual, automatic or robotic use), a FSSW process development case study is described to quantify the expected mechanical properties and tool life on a typical aluminium alloy and thickness combination (5754-O alloy, 1.1 mm thickness). The process development cycle incorporated a series of steps as follows: initial feasibility (lap shear strength versus plunge depth and cross tension strength, and rotation speed variation); design of experiments using various rotation speeds and plunge rates and depths; repeatability study; process sensitivity to determine the effects of outside variables; and tool life cycle tests.
5th International Symposium, 14-16 Sep 2004, Session 2B: Applications (Automotive and Aerospace), Paper 01
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