Tensile-Shear Mechanical Behaviors of Friction Stir Spot Weld and Adhesive Hybrid Joint: Experimental and Numerical Study
Abstract
:1. Introduction
2. Materials and Experiments
3. The Finite Element Modelling and Boundary Conditions
3.1. FE Modelling of Spot Weld
3.2. FE Modelling of Adhesive Layer
3.3. Load and Boundary Conditions
4. Results and Discussion
4.1. Hybrid Joint Defects
4.2. Mechanical Properties
4.3. Failure Mode
4.4. Finite Element Stress Analysis of Static Loading
5. Conclusions
- In FI joints, weld and adhesive layer were separate. Keyhole and hook defects appeared in the weld zone. The areas of material removed from the base metal were filled with adhesive. In the WT joints, the adhesive layer close to the weld zone was carbonized due to the welding heat. Under the rotating movement of welding tool, the adhesive impurities entered the SZ and HAZ regions of the weld, which degraded the mechanical performances of the WT joints;
- FI joints showed excellent performances in the static tensile-shear test compared to FSSW due to the synergistic effects of the weld and adhesive layer. The weld can block the adhesive crack, and the adhesive can optimize the stress distribution and offer high TSFL values due to the large bonded area. Compared to the FSSW joint, the TSFL value and stiffness of the FI joint were increased by 2.7 and 1.1 times. On the contrary, the WT process weakened the load capacity of the joint. As the rotation speed increased from 800 to 1600 rpm, the TSFL of the WT joint decreased from 3.99 to 2.57 kN;
- Although FI joints exhibited a slightly lower TSFL value than AB joints, due to the higher failure displacements, the energy absorption of the FI joint was 1.89 times higher than that of AB. However, due to internal defects, WT joints displayed the lowest energy absorption among the four types of joint;
- The FI joint presented a hybrid failure mode, which was composed of the cohesive failure within the adhesive layer and the ductile fracture in the weld zone; however, the adhesive closed to the weld zone showed carbonization in WT joints, which exhibited cleavage failure characteristics;
- In FI joints, the adhesive layer decreased the stress concentration in the FSSW weld. FE results show that under 2 kN tensile-shear load, the adhesive reduced the equivalent stress at the joint lap area from 176.44 to 55.95 MPa. Meanwhile, the maximum tensile stress in the FI joint occurred at the edge of the overlap area in the tensile direction. The FI joints reduced the tensile stress at the weld nugget edge from 243.09 to 15.5 MPa;
- In general, the performances of the FI joint are much superior to the FSSW joint. Moreover, the use of the FI process for aluminum alloy connection is strongly recommended, especially in crucial structure areas.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Young’s Modulus (GPa) | Yield Strength (MPa) | Ultimate Tensile Strength (MPa) | Elongation at 50 mm Gauge (%) | Section Shrinkage (%) |
---|---|---|---|---|
69.8 | 241 | 320 | 14.9 | 34.7 |
Regions | BZ [22,34] | HAZ | TMAZ | SZ | |
---|---|---|---|---|---|
Plastic flow law [36], | Initial yield strength, (MPa) | 241.2 | 233.6 | 246.4 | 246.9 |
Hardening constant, B | 403.1 | 390.4 | 411.9 | 412.8 | |
Hardening exponent, n | 0.487 | 0.487 | 0.487 | 0.487 | |
Tensile strength (MPa) | 367.7 | 356.1 | 375.7 | 376.5 |
Density 1 (Kg/m3) | Young’s Modulus E (GPa) | Poisson’s Ratio v | Lap Shear Strength (MPa) | Tensile Strength (MPa) |
---|---|---|---|---|
1150 | 2.25 | 0.4 | 241.325 | 12.87 |
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Yu, G.; Chen, X.; Zhang, B.; Pan, K.; Yang, L. Tensile-Shear Mechanical Behaviors of Friction Stir Spot Weld and Adhesive Hybrid Joint: Experimental and Numerical Study. Metals 2020, 10, 1028. https://doi.org/10.3390/met10081028
Yu G, Chen X, Zhang B, Pan K, Yang L. Tensile-Shear Mechanical Behaviors of Friction Stir Spot Weld and Adhesive Hybrid Joint: Experimental and Numerical Study. Metals. 2020; 10(8):1028. https://doi.org/10.3390/met10081028
Chicago/Turabian StyleYu, Guishen, Xin Chen, Biao Zhang, Kaixuan Pan, and Lifei Yang. 2020. "Tensile-Shear Mechanical Behaviors of Friction Stir Spot Weld and Adhesive Hybrid Joint: Experimental and Numerical Study" Metals 10, no. 8: 1028. https://doi.org/10.3390/met10081028
APA StyleYu, G., Chen, X., Zhang, B., Pan, K., & Yang, L. (2020). Tensile-Shear Mechanical Behaviors of Friction Stir Spot Weld and Adhesive Hybrid Joint: Experimental and Numerical Study. Metals, 10(8), 1028. https://doi.org/10.3390/met10081028