Development and characterization of dissimilar joint between AA2024-T3 and AA6061-T6 by modified friction stir clinching process

• Published in: Vacuum Vol. 176; p. 109298
• Main Authors: Paidar, M., Vaira Vignesh, R., Moharrami, A., Ojo, O.O., Jafari, A., Sadreddini, S.
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.06.2020
• Subjects: Aluminum; Dissimilar; Friction stir clinching; Microstructure; Welding; Dissimilar; Friction stir clinching; Welding; Microstructure; Aluminum
• ISSN: 0042-207X; 1879-2715
• DOI: 10.1016/j.vacuum.2020.109298

Friction stir spot welding (FSSW) is one of the effective solid-state welding strategies to achieve good joint efficiency between dissimilar aluminum alloys. However, the formation of tool-induced keyhole (a stress raiser) is inevitable during the FSSW process. This study explores the possibility of eliminating keyhole with the aim of improving the properties of the joint by Modified Friction Stir Clinching (MFSC) process. The tensile-shear and cross-tension strengths of the MFSC joints are 83% and 50% higher than that of the specimens joined by FSSW. The article presents a comprehensive analysis of the material flow characteristics, microstructural evolution, and tensile properties of the dissimilar joints between AA2024-T3 and AA6061-T6 that was enabled by the MFSC process. •AA2024-T3 and AA6061-T6 was successfully joined by Modified Friction Stir Clinching (MFSC) process.•MFSC process could completely omit the keyhole in the joint.•The study of mechanical properties vividly show that an increase in strength of welds made by MFSC process (enhanced approximately twice) when compared with conventional FSSW joints.