Properties and optimization of friction stir spot welded aluminum alloy 3003-H14

Abstract The lightweighting potential in modern manufacturing has been enhanced via the emergence of novel friction stir spot welding approaches by eliminating the conventional joining challenges of aluminum alloys. Optimizing the tool profile of friction stir spot welded joints is thus essential due to the direct controlling influence of tool morphology on material flow, bonding and weld quality. Therefore, this study examines the optimization of friction stir spot welded 1 mm thick 3003-H14 wrought aluminum alloy, by using a cylindrically threaded pin tool morphology and the Taguchi optimization methodology. Tool rotational speed, plunge depth and dwell time are utilized as welding parameters, while maximum shear failure load is employed as the response in this study. Analysis of variance (ANOVA) is employed to systematically investigate the main effect and interaction effect of welding parameters on weld performance. A maximum shear failure load of 2530 N was attained at a parameter combination of 1.50...