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As the automotive industry transitions to aluminumAluminum body panels, new and innovative joiningJoining technologies are under development to combat the challenges traditional fusion welding techniques face in aluminumAluminum. Refill Friction Stir Spot Welding (RFSSW) is a novel solid-state joiningJoining process that is well-suited for automotive joints in AA6061AA6061-T4. This paper presents a comprehensive analysis of eight RFSSW joints, ranging in total thickness from 2.0 to 5.7 mm. These material thickness combinations are sourced directly from Toyota’s current manufacturing processes. The microstructureMicrostructure and mechanical performance of the welds are evaluated. The microstructureMicrostructure is analyzed via optical microscopy, CT scanning, and microhardness testing. The mechanical propertiesMechanical properties are quantified through quasi-static tensile and fatigue testing. Surface topography is also reported.

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Refill Friction Stir Spot Welding in AA6061-T4 Automotive Sheets

  • 会议论文

  • 发表日期：

    2025年

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  • Taylor Smith,
  • Damon Gale,
  • Kate Namola,
  • Jeremy Coyne,
  • Yuri Hovanski

摘要

As the automotive industry transitions to aluminumAluminum body panels, new and innovative joiningJoining technologies are under development to combat the challenges traditional fusion welding techniques face in aluminumAluminum. Refill Friction Stir Spot Welding (RFSSW) is a novel solid-state joiningJoining process that is well-suited for automotive joints in AA6061AA6061-T4. This paper presents a comprehensive analysis of eight RFSSW joints, ranging in total thickness from 2.0 to 5.7 mm. These material thickness combinations are sourced directly from Toyota’s current manufacturing processes. The microstructureMicrostructure and mechanical performance of the welds are evaluated. The microstructureMicrostructure is analyzed via optical microscopy, CT scanning, and microhardness testing. The mechanical propertiesMechanical properties are quantified through quasi-static tensile and fatigue testing. Surface topography is also reported.