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Effects of Process Parameters on Friction Stir Spot Welding of Aluminum Alloy to Advanced High-Strength Steel

[+] Author Affiliations
Kai Chen, Xun Liu, Jun Ni

University of Michigan, Ann Arbor, MI

Paper No. MSEC2016-8589, pp. V001T02A011; 9 pages
  • ASME 2016 11th International Manufacturing Science and Engineering Conference
  • Volume 1: Processing
  • Blacksburg, Virginia, USA, June 27–July 1, 2016
  • Conference Sponsors: Manufacturing Engineering Division
  • ISBN: 978-0-7918-4989-7
  • Copyright © 2016 by ASME


Friction stir spot welding (FSSW) process has been successfully applied for joining aluminum alloy 6061 to TRIP 780/800 steel. Effects of tool plunge speed and dwell time on the weld strength were studied through design of experiments and analysis of variance. It is shown that dwell time is a more dominant parameter in affecting the weld strength than plunge speed. Cross sections of weld specimens show the formation of hook with a swirling structure. Higher magnified SEM view with EDS analysis reveals the swirling structure to be composed of alternating thin layers of steel and Al-Fe intermetallic compounds (IMCs). During tensile shear test, cross nugget failure is the only failure mode. Cracks are initiated in the swirling structure at the tensile side of the weld nugget and cleavage feature can be observed on the fractured surface.

Copyright © 2016 by ASME



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