Wear mechanisms and failure analysis of a tool used in refill friction stir spot welding of AA6061-T6

被引:3
作者
Fritsche, S. [1 ]
Schindler, F. [1 ]
de Carvalho, W. S. [1 ]
Amancio-Filho, S. T. [1 ]
机构
[1] Graz Univ Technol, Inst Mat Sci Joining & Forming, BMK Endowed Professorship Aviat, Graz, Austria
关键词
Refill friction stir spot welding; Solid-state welding; Tool wear; Aluminium alloys; Failure analysis; ALUMINUM; MICROSTRUCTURE; STEEL; INTERFACE;
D O I
10.1016/j.wear.2024.205610
中图分类号
TH [机械、仪表工业];
学科分类号
0802 ;
摘要
Investigating tool wear in refill friction stir spot welding (RFSSW) is essential for understanding its limitations and improving its efficiency. Increasing the tool's service life is important to push the technology's readiness level and transfer the technology from the laboratory to industrial applications. In this study, the quasi-static lap shear performance of AA6061-T6 similar welded spots was investigated and tool wear was continuously monitored until tool failure at 3450 welding cycles. Furthermore, the fundamentals of the wear mechanisms in RFSSW were further elucidated. The investigation shows that it is possible to achieve steady quasi-static lap shear performance of the spot welds over advancing tool wear by adjusting the heat input to compensate for losses in frictional heat generation efficiency (related to tool profile changes by abrasion). A subsequent tool failure case analysis showed the main causes for the continuous wear degradation of the shoulder. Tool wear was driven by plastic deformation of the hot-work tool steel and subsequent break-out of tool steel ridges, introducing big hard particles into the contact region between the moving and rotating tools. In addition, the formation and detachment of Fe-Al intermetallic compounds counteract with the rotating tools and increase tool wear.
引用
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页数:12
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