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<p>Friction stir spot welding (FSSW), a derivative of friction stir welding (FSW), is a solid-state joining technique used to produce high-quality spot welds, especially in aluminum alloys. In this study, FSSW was applied to join 3-mm-thick AA6082-T6 plates under varying conditions. The effects of tool rotational speed, dwell time, and penetration rate were investigated to understand their influence on the temperature profile, microstructure, and mechanical properties. The highest dwell time resulted in the highest temperature. However, the maximum tensile/shear load (MTSL) occurred at the lowest rotational speed and dwell time combination. The optimized condition produced an MTSL 23 % higher than other cases. Lap-shear tests revealed two fracture modes: nugget pull-out and shear failure, depending on joint strength. The SZ/TMAZ interface showed a compact, refined microstructure with high hardness. Lower hardness in the TMAZ/HAZ zone was attributed to grain coarsening.</p>

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Effect of process parameters on heat input and mechanical properties of friction stir spot welded AA6082-T6 plates

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Ameni Houas,
  • Nejah Jemal,
  • Eric Fleury,
  • Zoubeir Bouaziz,
  • Hamid Zahrouni

摘要

Friction stir spot welding (FSSW), a derivative of friction stir welding (FSW), is a solid-state joining technique used to produce high-quality spot welds, especially in aluminum alloys. In this study, FSSW was applied to join 3-mm-thick AA6082-T6 plates under varying conditions. The effects of tool rotational speed, dwell time, and penetration rate were investigated to understand their influence on the temperature profile, microstructure, and mechanical properties. The highest dwell time resulted in the highest temperature. However, the maximum tensile/shear load (MTSL) occurred at the lowest rotational speed and dwell time combination. The optimized condition produced an MTSL 23 % higher than other cases. Lap-shear tests revealed two fracture modes: nugget pull-out and shear failure, depending on joint strength. The SZ/TMAZ interface showed a compact, refined microstructure with high hardness. Lower hardness in the TMAZ/HAZ zone was attributed to grain coarsening.