This study investigates the application of metal particles in spot friction welding (SFW), a semi-solid state sheet metal joining process, to create the localized metal matrix composite (MMC) for the improvement of lap-shear strength. Ancorsteel® 1000 particles, compressed around the axial center-line of the tool between the upper and lower sheets, was demonstrated to form a localized MMC and effective as the reinforcement particles in aluminum 6111-T4 alloy sheets. Results revealed that the particle MMC in SFW increased the maximum lap-shear by 20%. In the stir-zone, steel particle sizes were significantly reduced due to breaking by mechanical action. Analysis revealed an aluminum-ferrous solid solution formation around the steel particle and aluminum matrix interfaces. In the heat-affected zone along the joint line, steel particles retained their original sizes and reinforced the joint interface. The load deflection curve and cross-section micrographs of the failed lap-shear tensile specimens indicated that, for steel particle MMC samples, the crack path was longer. This was due to a localized MMC forming along the joint interface and was identified as the primary factor responsible for the increase in SFW lap-shear strength.
- Manufacturing Engineering Division
Spot Friction Welding Joint Strength Improvement Using Localized Metal Matrix Composite Formation
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Arul, SG, Kruger, GH, Miller, SF, Pan, T, & Shih, AJ. "Spot Friction Welding Joint Strength Improvement Using Localized Metal Matrix Composite Formation." Proceedings of the ASME 2009 International Manufacturing Science and Engineering Conference. ASME 2009 International Manufacturing Science and Engineering Conference, Volume 2. West Lafayette, Indiana, USA. October 4–7, 2009. pp. 11-18. ASME. https://doi.org/10.1115/MSEC2009-84126
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