Hybrid joining of cast aluminum and sheet steel using refill friction stir spot welding with strength enhancement via adhesive application
Tong Shen, Rafael Piccoli, Leonardo Hendler, Andre Barbosa, Ting Chen, Uceu Suhuddin, Massimo Cucco, Benjamin Klusemann
Abstract. This study investigates the hybrid joining of cast aluminum AlSi10Mg and DP600 steel using refill friction stir spot welding (refill FSSW) integrated with adhesive application. Box-Behnken Design (BBD) was employed for experimental design, enabling a detailed statistical investigation of the effects of process parameters on joint strength and macrostructure. The final correlations for predicting joint strength in both non-adhesive and adhesive-assisted configurations were obtained through regression analysis. Pre-clamping techniques, including clamping ring and full tool pre-clamp methods, were employed to improve adhesive squeezing. The results demonstrate that adhesive-assisted joints achieve significantly higher lap-shear strength, exceeding twice the strength of joints without adhesive. The findings contribute to advancing refill FSSW for multi-material applications, particularly in automotive structures.
Keywords
Dissimilar Welding, Refill Friction Stir Spot Welding, Cast Aluminum, Adhesive Application
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Tong Shen, Rafael Piccoli, Leonardo Hendler, Andre Barbosa, Ting Chen, Uceu Suhuddin, Massimo Cucco, Benjamin Klusemann, Hybrid joining of cast aluminum and sheet steel using refill friction stir spot welding with strength enhancement via adhesive application, Materials Research Proceedings, Vol. 54, pp 1469-1478, 2025
DOI: https://doi.org/10.21741/9781644903599-159
The article was published as article 159 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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