Skip to main content
SpringerLink
Log in

Friction stir clinching of alclad AA2024-T3 sheets

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Sakano R, Murakami K, Yamashita K, Hyoe T, et al. (2001) Development of spot FSW robot system for automobile body members. In: Proceedings of the 3rd international symposium of friction stir welding, Kobe, Japan, September 27–28, 2001

  2. Iwashita T (2003) Method and apparatus for joining. US Patent 6601751 B2, August 5, 2003

  3. Lin P-C, Pan J, Pan T (2008) Failure modes and fatigue life estimations of spot friction welds in lap-shear specimens of aluminum 6111-T4 sheets, part 1: welds made by a concave tool. Int J Fatigue 30:74–89

    Article  Google Scholar 

  4. Lin P-C, Pan J, Pan T (2008) Failure modes and fatigue life estimations of spot friction welds in lap-shear specimens of aluminum 6111-T4 sheets, part 2: welds made by a flat tool. Int J Fatigue 30:90–105

    Article  Google Scholar 

  5. Lin P-C, Su Z-M, He R-Y, Lin Z-L (2012) Failure modes and fatigue life estimations of spot friction welds in cross-tension specimens of aluminum 6061-T6 sheets. Int J Fatigue 38:25–35

    Article  Google Scholar 

  6. Resistance Welder Manufacturers’ Alliance (2003) Resistance welding manual, 4th edn. American Welding Society, Miami, Florida

    Google Scholar 

  7. Shen Z, Yang X, Zhang Z, Cui L et al (2013) Microstructure and failure mechanisms of refill friction stir spot welded 7075-T6 aluminum alloy joints. Mater Des 44:476–486

    Article  Google Scholar 

  8. Zhao YQ, Liu HJ, Lin Z, Chen SX et al (2014) Microstructures and mechanical properties of friction spot welded Alclad 7B04-T74 aluminium alloy. Sci Technol Weld Join 19:617–622

    Article  Google Scholar 

  9. Tweedy B, Widener C, Burford D (2007) The effect of surface treatments on the faying surface of friction stir spot welds. In: Rajiv SM, Murray WM, Thomas JL, Kumar VJ (eds) Friction stir welding and processing IV. TMS, Warrendale, pp 333–340

    Google Scholar 

  10. Brown J, Widener C, Moore G, Poston K et al (2009) Evaluation of swept friction stir spot welding in Al 2219–T6. In: Rajiv SM, Murray WM, Thomas JL (eds) Friction stir welding and processing V. TMS, Warrendale, pp 215–223

    Google Scholar 

  11. Brown J, Widener C, Burford D, Horn W et al (2009) Corrosion and fatigue evaluation of swept friction stir spot welding through sealants and surface treatments. In: Rajiv SM, Murray WM, Thomas JL (eds) Friction stir welding and processing V. TMS, Warrendale, pp 273–282

    Google Scholar 

  12. Su Z-M, He R-Y, Lin P-C, Dong K (2015) Fatigue analyses for swept friction stir spot welds in lap-shear specimens of alclad 2024-T3 aluminum sheets. Int J Fatigue 61:129–140

    Article  Google Scholar 

  13. Su Z-M, He R-Y, Lin P-C, Dong K (2016) Fatigue of alclad AA2024-T3 swept friction stir spot welds in cross-tension specimens. J Mater Process Technol 236:162–175

    Article  Google Scholar 

  14. Moria K, Abea Y, Katob T (2012) Mechanism of superiority of fatigue strength for aluminium alloy sheets joined by mechanical clinching and self-pierce riveting. J Mater Process Technol 212:1900–1905

    Article  Google Scholar 

  15. Lee C-J, Kim J-Y, Lee S-K, Ko D-C et al (2010) Design of mechanical clinching tools for joining of aluminium alloy sheets. Mater Des 31:1854–1861

    Article  Google Scholar 

  16. Su Z-M, Qiu Q-H, Lin P-C (2016) Design of friction stir spot welding tools by using a novel thermal-mechanical approach. Mater 9:677–692

    Article  Google Scholar 

  17. Aoh J-N, Lin P-C (2009) Process development of FSW/FSSW on complex curvilinear surface components. AIDC Technical Report, Aerospace Industrial Development Corporation

Download references

Author information

Authors and Affiliations

  1. Advanced Institute of Manufacturing with High-tech Innovations, National Chung Cheng University, Chia-Yi, 62102, Taiwan

    P.-C. Lin & S.-M. Lo

  2. Department of Mechanical Engineering, National Chung Cheng University, Chia-Yi, 62102, Taiwan

    P.-C. Lin & S.-M. Lo

Authors
  1. P.-C. Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S.-M. Lo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P.-C. Lin.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lin, PC., Lo, SM. Friction stir clinching of alclad AA2024-T3 sheets. Int J Adv Manuf Technol 92, 2425–2437 (2017). https://doi.org/10.1007/s00170-017-0337-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0337-7

Keywords

Search

Navigation