The exit-hole in friction stir spot welded(FSSWed) 2024-T4 aluminum alloy joints was successfully repaired by using a three-phase secondary rectification resistance spot welding machine, which is termed as filling exi...The exit-hole in friction stir spot welded(FSSWed) 2024-T4 aluminum alloy joints was successfully repaired by using a three-phase secondary rectification resistance spot welding machine, which is termed as filling exit-hole based on resistance welding(FEBRW). The filling dynamic behavior of force was recorded by a device monitoring. Optical microscope(OM), electron backscatter diffraction(EBSD), and tensile shear tests and finite element modelling were conducted to investigate the repairing stages and bonding mechanisms of the repaired joints in detail. Results showed that exit-hole was completely filled and repaired experiencing three stages. Metallurgical bonding was achieved between plug and exit-hole wall in two forms, including melting bonding in the middle of the joints and partial diffusion bonding on both the upper and bottom of the joints. The highest tensile shear strength of the repaired joints was 7.43 kN, which was 36.3% higher than that of the as welded joints. Resistance welding paves an efficient way to repair the exit-hole in FSSWed joints.展开更多
Keyhole at the end of a weld prepared by friction stir welding(FSW)is one of the major issues that impede the application of FSW.To address this issue,a keyhole filling technique was proposed in this paper,which is ba...Keyhole at the end of a weld prepared by friction stir welding(FSW)is one of the major issues that impede the application of FSW.To address this issue,a keyhole filling technique was proposed in this paper,which is based on the principles of resistance spot welding(RSW).A three-phase secondary rectifier resistance spot welder was applied as the experimental instrument for filling the keyhole in the center of friction stir spot weld(FSSW).The test sheet is a 2024-T4 aluminium alloy with a thickness of 6.0mm.The experiments results show that the filled joint strength is improved by 26.12%since the area is increased for the plug in the keyhole.And there are two kinds of dimples in the tensile fracture-equiaxial dimples and long dimples.The filled joint involves the fusion welding zone(FWZ),pressure welding zone(PWZ),melted plug zone(MPZ),and plastic deformation zone(PDZ).The FWZ and the PWZ is the melting bond and diffusion bond between the plug and keyhole,respectively.The MPZ is the center part and the PDZ is upper or lower part of the plug.展开更多
The ultra-fine grain （UFG） steel is welded by using resistance spot welding technique with or without requirement of upsetting force. Metallographic inspection shows that the grain size of weld nugget is larger than...The ultra-fine grain （UFG） steel is welded by using resistance spot welding technique with or without requirement of upsetting force. Metallographic inspection shows that the grain size of weld nugget is larger than that of the base metal and the microstructure is altered significantly. In addition, contracting defects such as air holes can be found in the nugget center. The experiments show that the defects can be effectively avoided by the technique of adding upsetting force during the nugget cooling and crystallizing processes. In tensile shear tests, the welding joint starts to crack from the inner edge of the corona bond. The results of micro-hardness tests show that the newly born martensite structure dramatically improves the hardness of the joint. Under the interactions between residual stresses and regenerated fine grains, the micro-hardness of the heat-affected zone （ HAZ ） is lower than that of the nugget, but evidently higher than that of the base metal.展开更多
基金financially supported by the National Natural Science Foundation of China (No. 51874179)。
文摘The exit-hole in friction stir spot welded(FSSWed) 2024-T4 aluminum alloy joints was successfully repaired by using a three-phase secondary rectification resistance spot welding machine, which is termed as filling exit-hole based on resistance welding(FEBRW). The filling dynamic behavior of force was recorded by a device monitoring. Optical microscope(OM), electron backscatter diffraction(EBSD), and tensile shear tests and finite element modelling were conducted to investigate the repairing stages and bonding mechanisms of the repaired joints in detail. Results showed that exit-hole was completely filled and repaired experiencing three stages. Metallurgical bonding was achieved between plug and exit-hole wall in two forms, including melting bonding in the middle of the joints and partial diffusion bonding on both the upper and bottom of the joints. The highest tensile shear strength of the repaired joints was 7.43 kN, which was 36.3% higher than that of the as welded joints. Resistance welding paves an efficient way to repair the exit-hole in FSSWed joints.
文摘Keyhole at the end of a weld prepared by friction stir welding(FSW)is one of the major issues that impede the application of FSW.To address this issue,a keyhole filling technique was proposed in this paper,which is based on the principles of resistance spot welding(RSW).A three-phase secondary rectifier resistance spot welder was applied as the experimental instrument for filling the keyhole in the center of friction stir spot weld(FSSW).The test sheet is a 2024-T4 aluminium alloy with a thickness of 6.0mm.The experiments results show that the filled joint strength is improved by 26.12%since the area is increased for the plug in the keyhole.And there are two kinds of dimples in the tensile fracture-equiaxial dimples and long dimples.The filled joint involves the fusion welding zone(FWZ),pressure welding zone(PWZ),melted plug zone(MPZ),and plastic deformation zone(PDZ).The FWZ and the PWZ is the melting bond and diffusion bond between the plug and keyhole,respectively.The MPZ is the center part and the PDZ is upper or lower part of the plug.
文摘The ultra-fine grain （UFG） steel is welded by using resistance spot welding technique with or without requirement of upsetting force. Metallographic inspection shows that the grain size of weld nugget is larger than that of the base metal and the microstructure is altered significantly. In addition, contracting defects such as air holes can be found in the nugget center. The experiments show that the defects can be effectively avoided by the technique of adding upsetting force during the nugget cooling and crystallizing processes. In tensile shear tests, the welding joint starts to crack from the inner edge of the corona bond. The results of micro-hardness tests show that the newly born martensite structure dramatically improves the hardness of the joint. Under the interactions between residual stresses and regenerated fine grains, the micro-hardness of the heat-affected zone （ HAZ ） is lower than that of the nugget, but evidently higher than that of the base metal.
