Friction stir spot welding (FSSW) is a solid-state joining process and a rapidly growing dissimilar material welding technology for joining metallic alloys in the automotive industry. Welding tool shape and process conditions must be appropriately controlled to obtain high bonding characteristics. In this study, FSSW is performed on dissimilar materials AA5052-H32 aluminum alloy sheet and SPRC440 steel sheet, and the influence of the shape of joining tool and tool insertion depth during joining is investigated. A new intermetallic compound is produced at the aluminum and steel sheets joint. When the insertion depth of the tool is insufficient, the intermetallic compound between the two sheets did not form uniformly. As the insertion depth increased, the intermetallic compound layer become uniform and continuous. The joint specimen shows higher values of tensile shear load as the diameter and insertion depth of the tool increase. This shows that the uniform formation of the intermetallic compound strengthens the bonding force between the joining specimens and increases the tensile shear load.

In this study, we investigated the change in fracture properties after friction stir welding on Al606. In the L-T direction test, the fracture toughness of the unwelded base material was 275 MPa, and the specimen subjected to friction stir welding (FSW) was 227 MPa, showing that the fracture toughness decreased significantly with friction stir welding. In the T-L direction test, the difference between the base material and the weld material was not large, but the fracture toughness was shown to decrease during welding. In the comparison of the L-T direction and the T-L direction, it was found that both the base material and the weld material showed high fracture toughness in the L-T direction.In this study, the following conclusions were obtained after friction stir welding of Al 6061-T6.

Power converter devices require a high level of quality because they have a high direct connection with vehicle operation. Therefore, structural bonding was carried out by friction stir welding with excellent mechanical properties. Friction stir welding can cause structural deflection depending on the load of the welding tool, so it is important to control this for high quality flatness. In this study, pre-welding was performed before welding to minimize deflection generated during welding. And deflection reduction data according to the location of pre-welding were analyzed through dynamic analysis. As a result, based on computerized data rather than experimental data an optimized position of pre-welding was secured to minimize the deflection that occurs during friction stir welding. Through this, a process guide that enables high quality structural bonding was presented.

In this study, the following conclusions were obtained after friction stir welding of Al 6061-T651. 1) The organization of the welding unit is largely divided into four parts, the Stir zone, themal-mechanical affected zone, heat affected zone, it was confirmed that it is clearly separated into the material portion. 2) As a result of observing the hardness test results of the welding unit, the minimum hardness value was about 45Hv, which was significantly lower than the hardness of the base material about 72Hv. 3) The tensile strength of the welding part was about 2/3 compared to the tensile strength of the base material.

알루미늄합금 6061-T6 판재에 대하여 마찰교반용접과 텅스텐 이너트 가스 용접의 교차 용접부의 미세조직과 기계적 특성에 있어서 용접 순서의 영향을 분석하기 위한 시험편을 성공적으로 제작하였다. FSW-ED 시험편이 다른 조합들보다 가장 좋은 기계적 특성을 나타내었다. 흥미롭게도, TIG-FSW ED 시험편이 FSW-TIG ED 시험편보다 높은 인장강도를 나타내었다. 용접부 경도의 경우, FSW 시편이 TIG-FSW 및 FSW-TIG 시험편보다 높은 값을 나타내었고, TIG-FSW 시험편이 FSW-TIG 시험편보다 높은 값을 나타내었다. FE-SEM을 이용한 인장 파면에 대한 관찰을 통하여, 모든 시험편에서 연성파괴를 나타내는 다양한 크기의 딤플들이 관찰되었다. FSW-TIG 시험편의 파면에서는 용융지(熔融池) 표면 영역에서 기공들이 관찰되는 반면, TIG-FSW 시험편에서는 기공의 형성은 관찰되지 않았다. 경도와 미세조직의 결과를 통해 TIG-FSW 공정이 FSW-TIG 공정보다 높은 인장강도를 확보할 수 있는 공정임을 확인하였다.

In this study, experiments and simulations were performed for fillet joint friction stir welding according to tool shape and welding conditions. Conventional butt friction stir welding has good weldability because heat is generated by friction with the bottom of the tool shoulder. However, in the case of fillet friction stir welding, the frictional heat is not sufficiently generated at the bottom of the tool shoulder due to the shape of the tool and the shape of the joint. Therefore, it is important to sufficiently generate frictional heat by slowing the welding speed as compared to butt welding. In this study, experiments and simulations were carried out on an aluminum battery housing made by friction stir welding an extruded material with a fillet joint. The temperature of the structure was measured using a thermocouple during welding, and the heat source was calculated through correlation analysis. Thermal elasto-plastic analysis of the structure was carried out using the calculated heat source and geometric boundary conditions. It is confirmed that the experimental results and the simulation results are well matched. Based on the results of the study, the deformation of the structure can be calculated through simulation even if the tool shape and welding process conditions change.

Recently, the use of non-ferrous metals has been increasing to lighten the weight of automobiles and parts. In particular, demand for non-ferrous alloy materials such as aluminum alloys and magnesium alloys is increasing. The purpose of this study is to calculate the optimization process of friction stir welding by using different materials of AA5052 and AA6061. By analyzing the reaction value of tensile strength and elongation by full factorial design and Custom Design Methodology. In other words, we analyzed the optimization process according to rotation speed, feed rate, tool angle and tool shape. In conclusion, the optimal process for tensile strength was achieved by using a tool with a rotation speed of 900 RPM, feed rate of 270, tool angle of 2.5° and a triangle tool. and The rotation speed was 1003 RPM, the feed rate was 314.5, tool angle of 1° and a triangle tool, it was able to get the maximum value of elongation when using a tool of the form.

In this study, the curvature FSW experiments were performed with the 2 mm thickness of Al 5083-O using by the 5 axis(X/Y/Z/A/C) position control system. For the mechanical test of the butt joints, the tungsten heavy alloy as the tool material without necessary after finishing the heat treatment such as quenching was used. In particular, the insertion depth and the welding speed was changed at the constant rotation speed in order to select the optimum FSW condition. The test results were visually satisfactory for the approximate joint length of 300 mm. Sound joint was formed at the condition of 1.9 mm-1000 rpm-100 mm/min and its tensile strength of joint was the most high almost the same as that of the base material.

In this study, the effect of the friction stir welding (FSW) was compared with that of the gas tungsten arc welding (GTAW) on the microstructure and microhardness of Cu-Ni alloy weldment. The weldment of 10 mm thickness was fabricated by FSW and GTAW, respectively. Both weldments were compared with each other by optical microstructure, microhardness test and grain size measurement. Results of this study suggest that the microhardness decreased from the base metal (BM) to the heat affected zone (HAZ) and increased at fusion zone (FZ) of GTAW and stir zone (SZ) of FSW. the minimum Hv value of both weldment was obtained at HAZ, respectively, which represents the softening zone, whereas Hv value of FSW weldment was little higher than that of GTAW weldment. These phenomena can be explained by the grain size difference between HAZs of each weldment. Grain size was increased at the HAZ during FSW and GTAW. Because FSW is a solid-state joining process obtaining the lower heat-input generated by rotating shoulder than heat generated in the arc of GTAW.

In this study, the cold rolled DP590 FSW joints were obtained by the position control type of the FSW machine and examined. The FSW weldability was investigated using the Si3N4 tool specially made by Cold Isostatic Press (CIP). Defect-free joints were formed at 180-300 mm/min at 800 rpm. However, a groove-like defect was observed along the joint line of the advancing side due to the insufficient material flow. In addition, the life of the Si3N4 tool was compared to that of the polycrystalline cubic boron nitride (PCBN) tool for the durability. The SI3N4 tool that was broken in which tool reached a length of 5 m and around half of the performance level of the PCBN tool.

In this study, the weldability of ADC12 FSW joints obtained by the load control type of the FSW machine is examined. The higher the tool plunge downforce the wider the range of the optimum FSW conditions is obtained. However, there is a limit of optimum range with increasing the tool plunge downforces. The three different types of defects are formed in ADC12 FSW joints, depending on the welding conditions. One is a large mass of flash due to the excess heat input, another is a cavity or groove-like defects caused by insufficient heat input and the other is a cavity caused by the abnormal stirring. As for the abnormal stirring, it is very clearly seen that the shape of the top part on the advancing side in the stir zone is completely different. For this type of defect, the effect of the tool plunge downforce is not significant, though the size of the defect due to insufficient heat input significantly is decreased with the increasing downforce

A5J32-T4 and A5052-H32 dissimilar aluminum alloy plates with thickness of 1.6 and 1.5 mm were welded by friction stir lap welding (FSLW). The FSLW were studied using different probe length tool and various welding conditions which is rotation speed of 1000, 1500 rpm and welding speed of 100 to 600 mm/min and material arrangement, respectively. The effects of plunge depth of tool and welding conditions on tensile properties and weld nugget formation. The results showed that three type nugget shapes such as hooking, void, sound have been observed with revolutionary pitch. This plunge depth and material arrangement were found to effect on the void and hooking for- mation, which in turn significantly influenced the mechanical properties. The maximum joint efficiency of the FSLWed plates was about 90% compared to base metal, A5052-H32 when the A5052-H32 was positioned upper plate and plunge depth was positioned at near interface between upper and lower plates.

선박 구조재료 FRP 재료의 대체 재료로 빠른 선속과 선적량 증가는 물론 재활용이 용이한 Al 선박으로 전환되고 있다. 본 논문에서는 인장실험을 통해 레저선박에 사용되는 5456-H116 합금에 대한 최적의 마찰교반용접 조건에서 프루브 직경의 효과를 기술하였다. 마찰교반용접에서 이송속도, 회전속도를 변수로 5 mm의 프루브 직경을 사용하여, 이송속도가 61 mm/min의 조건에서 가장 우수한 결과를 나타냈다. 프루브 직경 6 mm, 회전속도 170-210 rpm, 이송속도 15 mm/min 에서는 낮은 회전속도로 인하여 불충분한 용접열이 발생하여 거친 표면과 기공이 형성 되었다. 회전속도 500-800 rpm인 경우, 용접부에 칩이 관찰되었으며, 기공은 생기지 않았고, 용접표면은 우수하였으나 1100-2500 rpm에서는 지나친 용접열의 발생으로 많은 칩이 발생하였다. 열에 의한 영향은 용접 배면에서 관찰되었다. 이송속도가 15 mm/min에서 회전속도의 증가하게 되면 마찰이 증가함에 따라 용접열이 발생한다. 기계적 특성은 용접 입열량이 증가할수록 재질의 연화가 가속화되어 저하하였다.