Effect of Rotational Speed and Flat Tool Diameter on the Zn Distribution of the Dissimilar Metals Friction Stir Spot Welded between Aluminum Alloy 5083 H321 and Galvanized Steel

Abstract

Friction stir spot welding (FSSW) was developed to join the dissimilar materials as an alternative for replacing the resistance spot welding (RSW). In the case of dissimilar metals welded between aluminum and galvanized steel, Zn can decompose and diffuse in both steel and aluminum so it can increase the joint strength. Due to this reason, it is important to explore the Zn distribution based on the parameter of the friction stir spot welding. The lap joint configuration was used in this work where aluminum plate was placed on the top of steel. Aluminum thickness was 3 mm, while steel thickness was 1 mm. The constant depth of plunge, dwell time, and penetration rate were 2.7 mm, 3 seconds, and 0.9 mm/sec respectively. Flat tool with diameters of 10 mm, 12 mm and 14 mm were used for FSSW processes and for each flat tool diameter, four levels of the rotational speed of 1000 rpm, 1200 rpm, 1600 rpm and 2000 rpm were performed. The Zn distribution was evaluated using the SEM and EDS analysis. Due to the heat generation during FSSW process, materials around the tools will soften and then flow to follow the centrifugal force. The rotational speed and the flat tool diameter affected the distance and the shape of Zn diffusion flow. The distance of Zn diffusion both horizontal and vertical direction increased as increasing the rotational speed and the flat tool diameter.