A novel friction stir diffusion bonding process using convex-vortex pin tools

doi:10.1016/j.jmst.2020.01.042

Abstract

Abstract:

In this work, a novel friction stir diffusion bonding (FSDB) method was proposed to eliminate hook when joining thin sheets. Three tools, with several convex-vortex pins were innovatively designed to improve the diffusion bonding effect of the lap interface. Results showed that sound joints, excellently bonded at the lap interface and without hook, were obtained. The lap interfaces on the joints welded using the T-tool and F-tool almost remained intact, thereby indicating that they were formed by diffusion bonding. The material flow behavior was also simulated by FLUENT software and the results showed that the material flow along thickness was significantly enhanced by increasing the pin number. The joint welded by the T-tool showed shear fracture mode. Sound bonding was formed at the lap interface when using the F-tool and thus the joint showed tensile fracture.

Key words: Friction stir diffusion bonding, Convex-vortex pin, Hook, Material flow, Failure

S.D. Ji, Q. Wen, Z.W. Li. A novel friction stir diffusion bonding process using convex-vortex pin tools[J]. J. Mater. Sci. Technol., 2020, 48: 23-30.

Figures/Tables 13

Fig. 1. Schematic of FSDB.

Fig. 2. Tools used in this work: (a) T-tool, (b) F-tool and (c) S-tool.

Fig. 3. Cross-sections of FSLW joints using different tools: (a) T-tool, (b) F-tool, (c) S-tool, and (d) borders of the SZs.

Fig. 4. Temperatures of the testing points using the three tools.

Fig. 5. Widths of joint SZs along thickness welded using different tools.

Fig. 6. Magnified views of the joint at: (a) A, (b) B, (c) C, and (d) D in Fig. 3a, (e) E, (f) F, (g) G and (h) H in Fig. 3(c).

Fig. 7. Material flow behavior perpendicular to the welding direction by the: (a) T-tool, (b) F-tool, and (c) S-tool.

Fig. 8. Positions of different sections.

Fig. 9. Material flow velocity fields of section A using the (a) T-tool, (b) F-tool, and (c) S-tool, and of section B using the (d) T-tool, (e) F-tool, and (f) S-tool.

Fig. 10. Material flow model (a), the lap interface morphology using the S-tool (b), F-tool (c), and T-tool (d).

Fig. 11. Lap shear failure loads of the joints welded by different tools.

Fig. 12. Fracture locations of lap joints welded at 600?rpm using: (a) T-tool, (b) F-tool, (c) S-tool.

Fig. 13. Fracture morphologies of lap joints by using: (a) T-Tool, (b) F-tool and (c) S-tool.

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