

An efficient and productive joining technique to weld aluminium has become a priority challenge for promoting the use of aluminium in the electrical industry. One of the challenges is to obtain welds with superior mechanical properties with the consistent quality of weld surface as well as low electrical resistance. In this paper, the influence of rotational speed during the friction stir spot welding of AA 5754-H111 was studied to analyse the mechanical and electrical properties of the welds. The results from two rotational speeds (1000 rpm and 4500 rpm) are presented and compared to the base material. It was observed that the samples welded at 1000 rpm showed a higher average shear failure load (~ 1.1 kN) compared to the samples welded at 4500 rpm (~ 0.94 kN). The microhardness of the samples welded at 1000 rpm was higher than that of the base material, while the microhardness of samples welded at 4500 rpm was lower. It was also found that the friction welded sheets, regardless of the rotational speed used, showed increased electrical resistance compared to the base material, albeit this increase for the samples welded at 1000 rpm was about 42%, compared to samples welded at 4500 rpm where this increase was just 14%. © 2022, The Author(s).
| Engineering controlled terms: | FrictionFriction stir weldingMicrohardnessSpeedSpot weldingWelds |
|---|---|
| Engineering uncontrolled terms | Aluminium-alloy sheetsBase materialElectrical and mechanical propertiesElectrical industryElectrical resistancesFriction stirFriction stir spot weldingJoining techniquesRotational speedSpot welded |
| Engineering main heading: | Electric resistance |
| Funding sponsor | Funding number | Acronym |
|---|---|---|
| British Council See opportunities | ||
| Horizon 2020 Framework Programme See opportunities by H2020 | H2020 | |
| 451–03-68/2020–14/200156,200156 | ||
| CA18125,2022,CA16235,CA18224 | ||
| Royal Academy of Engineering See opportunities | TSP1332,IAPP18-19\295 | |
| UK Research and Innovation | EP/T024607/1,EP/T001100/1,EP/S013652/1,EP/L016567/1,EP/S036180/1 | UKRI |
| EP/R00661X/1 | ||
| London South Bank University | EP/V026402/1 | LSBU |
| European Association of National Metrology Institutes | EMPIR A185 | EURAMET |
| Royal Society See opportunities | NIF\R1\191571 | |
| Deutscher Akademischer Austauschdienst See opportunities by DAAD | CA15102 | DAAD |
All authors greatly acknowledge the financial support provided by the UKRI via Grants No. EP/L016567/1, EP/S013652/1, EP/S036180/1, EP/T001100/1 and EP/T024607/1, Transforming the Foundation Industries NetworkPlus Feasibility study award to LSBU (EP/V026402/1), the Royal Academy of Engineering via Grants No. IAPP18-19\\295 and TSP1332, EURAMET EMPIR A185 (2018), the EU Cost Action (CA15102, CA18125, CA18224 and CA16235), The Hubert Curien Partnership award 2022 from the British Council and the Newton Fellowship award from the Royal Society (NIF\\R1\\191571). Wherever applicable, the work made use of Isambard Bristol, UK, supercomputing service accessed by a Resource Allocation Panel (RAP) grant as well as ARCHER resources (Project e648).
Open Access funding enabled and organized by Projekt DEAL. The authors are grateful to the DAAD program for financial support to perform the experimental work. Specific thanks to the Royce PhD Equipment Access Scheme enabling access to TEM facilities at Royce@Cambridge via UKRI Grant EP/R00661X/1 and to the STSM support from Cost Action CA15102 (funded by H2020). Also, this paper has been supported by the Ministry of Education, Science and Technological Development through project no. 451\u201303-68/2020\u201314/200156: \u201CInnovative scientific and artistic research from the FTS activity domain.\u201D
Labus Zlatanovic, D.; Department of Production Technology, Technische Universität Ilmenau, Ilmenau, Germany;
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