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Friction Stir Welding and Processing X pp 67–75Cite as

High-Speed Friction Stir Lap Welding of Al Alloys

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Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

Friction stir lap welding (FSLW) with linear speed of 1 m/min or higher can open up opportunities for industrial implementation. This paper will provide an overview of several challenges and mitigation strategies to produce effective joints between several Al alloys. FSLW of Al alloys at high speed presents challenges including interface hook features and defects at the interface. 5xxx, 6xxx, and 7xxx Al alloys were joined and characterized. Load-bearing capacity in excess of 80% of base material strength has been demonstrated at the welding speed of 2 m/min for 6xxx and 5xxx similar lap joints . The effects of parameters like welding speed, RPM, tool geometry in material flow features, void volume, and hook geometry is investigated and this knowledge base is applied to improve the joint strength of 7xxx lap welds.

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References

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Acknowledgements

PNNL is operated by Battelle Memorial Institute for the U.S. Department of Energy under contract DE-AC05-76RL01830. This work was sponsored by S. Kleinbaum in association with the U.S. Department of Energy Office of Vehicle Technologies as part of the Lightweight Materials program along with contributions from participating entities including Honda R&D Americas, and Arconic Inc.

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Authors and Affiliations

  1. Pacific Northwest National Laboratory, 902 Battelle Boulevard, Richland, WA, 99354, USA

    Piyush Upadhyay, Xiao Li & Tim Roosendaal

Authors
  1. Piyush Upadhyay
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  2. Xiao Li
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  3. Tim Roosendaal
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Corresponding author

Correspondence to Piyush Upadhyay .

Editor information

Editors and Affiliations

  1. Brigham Young University, Provo, UT, USA

    Yuri Hovanski

  2. University of North Texas, Denton, TX, USA

    Rajiv Mishra

  3. Tohoku University, Sendai, Japan

    Yutaka Sato

  4. Pacific Northwest National Laboratory, Richland, WA, USA

    Piyush Upadhyay

  5. San Jose State University, San Jose, CA, USA

    David Yan

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© 2019 The Minerals, Metals & Materials Society

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Cite this paper

Upadhyay, P., Li, X., Roosendaal, T. (2019). High-Speed Friction Stir Lap Welding of Al Alloys. In: Hovanski, Y., Mishra, R., Sato, Y., Upadhyay, P., Yan, D. (eds) Friction Stir Welding and Processing X. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-05752-7_7

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