A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications
To reduce vehicle weight and improve energy efficiency, automotive manufacturers are increasingly using aluminum body panels. However, the traditional joining method, Resistance Spot Welding (RSW), presents challenges like weld porosity and electrode degradation when used with aluminum. These issues...
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MDPI AG
2024-11-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/8/6/260 |
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| author | Damon Gale Taylor Smith Yuri Hovanski Kate Namola Jeremy Coyne |
| author_facet | Damon Gale Taylor Smith Yuri Hovanski Kate Namola Jeremy Coyne |
| author_sort | Damon Gale |
| collection | DOAJ |
| description | To reduce vehicle weight and improve energy efficiency, automotive manufacturers are increasingly using aluminum body panels. However, the traditional joining method, Resistance Spot Welding (RSW), presents challenges like weld porosity and electrode degradation when used with aluminum. These issues have driven the industry to explore alternative, more effective methods for joining aluminum in vehicle manufacturing such as Refill Friction Stir Spot Welding (RFSSW). This research reports on a comparison of the microstructure and mechanical properties of welds made with RSW and RFSSW in AA6061-T4 automotive sheets. This comparison includes CT scanning, optical and SEM imaging, statistical microscopy, hardness testing, tensile testing, and fatigue testing. The results showed that RFSSW produced fully consolidated welds with a refined, equiaxed grain structure that outperformed RSW’s dendritic grain structure by as much as 73% in tensile testing and 2600% in fatigue testing. These results suggest that future designs utilizing RFSSW could incorporate fewer joints, reducing processing time, energy consumption, and tool wear. Cost studies also found that RFSSW consumes 2.5% of the energy that RSW does per joint, demonstrating that RFSSW is positioned as the preferred method for joining aluminum automotive sheets. |
| format | Article |
| id | doaj-art-b5725b2ad5ca429bb626b330b37e5448 |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-b5725b2ad5ca429bb626b330b37e54482024-12-27T14:32:49ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-11-018626010.3390/jmmp8060260A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive ApplicationsDamon Gale0Taylor Smith1Yuri Hovanski2Kate Namola3Jeremy Coyne4Department of Manufacturing Engineering, Ira A Fulton College of Engineering, Brigham Young University, CTB 265, Provo, UT 84604, USADepartment of Manufacturing Engineering, Ira A Fulton College of Engineering, Brigham Young University, CTB 265, Provo, UT 84604, USADepartment of Manufacturing Engineering, Ira A Fulton College of Engineering, Brigham Young University, CTB 265, Provo, UT 84604, USAToyota Motor North America, 151 Engineering Wy, Georgetown, KY 40324, USAToyota Motor North America, 151 Engineering Wy, Georgetown, KY 40324, USATo reduce vehicle weight and improve energy efficiency, automotive manufacturers are increasingly using aluminum body panels. However, the traditional joining method, Resistance Spot Welding (RSW), presents challenges like weld porosity and electrode degradation when used with aluminum. These issues have driven the industry to explore alternative, more effective methods for joining aluminum in vehicle manufacturing such as Refill Friction Stir Spot Welding (RFSSW). This research reports on a comparison of the microstructure and mechanical properties of welds made with RSW and RFSSW in AA6061-T4 automotive sheets. This comparison includes CT scanning, optical and SEM imaging, statistical microscopy, hardness testing, tensile testing, and fatigue testing. The results showed that RFSSW produced fully consolidated welds with a refined, equiaxed grain structure that outperformed RSW’s dendritic grain structure by as much as 73% in tensile testing and 2600% in fatigue testing. These results suggest that future designs utilizing RFSSW could incorporate fewer joints, reducing processing time, energy consumption, and tool wear. Cost studies also found that RFSSW consumes 2.5% of the energy that RSW does per joint, demonstrating that RFSSW is positioned as the preferred method for joining aluminum automotive sheets.https://www.mdpi.com/2504-4494/8/6/260refill friction stir weldingresistance spot weldingautomotive joiningAA6061 |
| spellingShingle | Damon Gale Taylor Smith Yuri Hovanski Kate Namola Jeremy Coyne A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications Journal of Manufacturing and Materials Processing refill friction stir welding resistance spot welding automotive joining AA6061 |
| title | A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications |
| title_full | A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications |
| title_fullStr | A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications |
| title_full_unstemmed | A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications |
| title_short | A Comparison of the Microstructure and Mechanical Properties of RSW and RFSSW Joints in AA6061-T4 for Automotive Applications |
| title_sort | comparison of the microstructure and mechanical properties of rsw and rfssw joints in aa6061 t4 for automotive applications |
| topic | refill friction stir welding resistance spot welding automotive joining AA6061 |
| url | https://www.mdpi.com/2504-4494/8/6/260 |
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