In order to improve corrosion resistance, alclad aluminum sheets, which are formed from pure aluminum surface layers cladded on high-strength aluminum alloy core sheets, are widely used in industry. However, in the conventional welding process, the alclad layer on the faying surface is a tough barrier, which significantly reduces weld strength. Therefore, friction stir clinching (FSC), a variant of friction stir spot welding (FSSW), was developed for joining alclad AA2024-T3 sheets. In this study, a FSC tool with a flat shoulder and a smooth probe, and a FSC die with a grooved circular cavity were used to make joints. The effects of important processing parameters on the mechanical performance of FSC joints were studied. A set of valid processing parameters was obtained. Untested and tested FSC joints were then examined using optical micrographs. The results indicated that the mechanical interlock and alclad layer shape of FSC joints are strongly correlated with their fracture and fatigue performance. Finally, a comparison with the mechanical performance of solid rivets and swept friction stir spot welds (swept-FSSWs) confirmed the feasibility of the FSC process for alclad aluminum sheets.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Apr 3, 2017
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