TWI

With regard to the development of dissimilar aluminium-steel joint fabrication for automotive applications such as body-in-white, an investigation incorporating experiment and numerical simulation was undertaken to examine the dissimilar friction stir spot welding (FSSW) of two aluminium alloys to various steels. The aluminium alloys studied were Al 5182 (Al, 4.18%Mg) and Al 6016 (Al, 0.6%Mg, 0.54%Si), while the steels were DC04, HSLA 340 and DP 600. Welding was conducted on a homemade machine equipped with laser sensors and load cells at a spindle rotational speed of 1000-2000 rpm. Welded joint mechanical properties were characterised by hardness measurements as well as tensile strength and shear tests. The relationship between tensile strength and process parameters (rotational speed, plunge depth and dwell time) was studied by a design of experiment method. Experimental results were compared with Simufact Forming finite element software simulations.

12th International Symposium, 26-28 Jun 2018, Session 11B: FSSW II, Paper 03