Skip to main content
Top

12-04-2024 | Review

Refill friction stir spot welding (RFSSW): a review of processing, similar/dissimilar materials joining, mechanical properties and fracture mechanism

Authors: Yun-qiang Zhao, Hao-kun Yang, Aloshyn Andriia, Hong-hang Lo, Jia-xin Li

Published in: Journal of Iron and Steel Research International

Login to get access

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Refill friction stir spot welding (RFSSW) provides a novel method to join similar and/or dissimilar metallic materials without a key-hole in the center of the joint. Having the key-hole free characterization, the similar/dissimilar RFSSW joint exhibits remarkable and endurable characteristics, including high shear strength, long fatigue life, and strong corrosion resistance. In the meanwhile, as the key-hole free joint has different microstructures compared with conventional friction stir spot welding, thus the RFSSW joint shall possess different shear and fatigue fracture mechanisms, which needs further investigation. To explore the underlying failure mechanism, the similar/dissimilar metallic material joining parameters and pre-treatment, mechanical properties, as well as fracture mechanisms under this novel technology will be discussed. In details, the welding tool design, welding parameters setting, and the influence of processing on the lap shear and fatigue properties, as well as the corrosion resistance will be mainly discussed. Moreover, the roadmap of RFFSW is also discussed.
Literature
[1]
go back to reference R. Karthikeyan, V. Balasubramanian, Int. J. Adv. Manuf. Technol. 51 (2010) 173–183.CrossRef R. Karthikeyan, V. Balasubramanian, Int. J. Adv. Manuf. Technol. 51 (2010) 173–183.CrossRef
[2]
go back to reference W. Yuan, R.S. Mishra, B. Carlson, R. Verma, R.K. Mishra, Mater. Sci. Eng. A 543 (2012) 200–209.CrossRef W. Yuan, R.S. Mishra, B. Carlson, R. Verma, R.K. Mishra, Mater. Sci. Eng. A 543 (2012) 200–209.CrossRef
[3]
go back to reference M. Yu, H. Zhao, Z. Zhang, L. Zhou, X. Song, J. Manuf. Process. 77 (2022) 1–12.CrossRef M. Yu, H. Zhao, Z. Zhang, L. Zhou, X. Song, J. Manuf. Process. 77 (2022) 1–12.CrossRef
[4]
go back to reference R. Heideman, C. Johnson, S. Kou, Sci. Technol. Weld. Join. 15 (2010) 597–604.CrossRef R. Heideman, C. Johnson, S. Kou, Sci. Technol. Weld. Join. 15 (2010) 597–604.CrossRef
[5]
go back to reference A. Gerlich, P. Su, T. North, G. Bendzsak, Materials forum 2005 (2005) 290–294. A. Gerlich, P. Su, T. North, G. Bendzsak, Materials forum 2005 (2005) 290–294.
[6]
go back to reference Z. Shen, Y. Ding, A.P. Gerlich, Crit. Rev. Solid State Mater. Sci. 45 (2020) 457–534.CrossRef Z. Shen, Y. Ding, A.P. Gerlich, Crit. Rev. Solid State Mater. Sci. 45 (2020) 457–534.CrossRef
[7]
[8]
go back to reference J. Yamaguchi, in: Toyota Prius: AEI best engineered vehicle 2004, Automotive Engineering International, Stuttgart, Germany, 2004, pp. 24. J. Yamaguchi, in: Toyota Prius: AEI best engineered vehicle 2004, Automotive Engineering International, Stuttgart, Germany, 2004, pp. 24.
[9]
go back to reference R. Sakano, in: Proceedings of the 3rd International Symposium of Friction Stir Welding, Kobe, Japan, 2004, pp. 10020488538. R. Sakano, in: Proceedings of the 3rd International Symposium of Friction Stir Welding, Kobe, Japan, 2004, pp. 10020488538.
[10]
go back to reference D. Bakavos, Y. Chen, L. Babout, P. Prangnell, Metall. Mater. Trans. A 42 (2011) 1266–1282.CrossRef D. Bakavos, Y. Chen, L. Babout, P. Prangnell, Metall. Mater. Trans. A 42 (2011) 1266–1282.CrossRef
[11]
go back to reference N.T. Nguyen, D.Y. Kim, H.Y. Kim, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 225 (2011) 1746–1756.CrossRef N.T. Nguyen, D.Y. Kim, H.Y. Kim, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 225 (2011) 1746–1756.CrossRef
[12]
go back to reference S. Venukumar, S. Yalagi, S. Muthukumaran, Trans. Nonferrous Met. Soc. China 23 (2013) 2833–2842.CrossRef S. Venukumar, S. Yalagi, S. Muthukumaran, Trans. Nonferrous Met. Soc. China 23 (2013) 2833–2842.CrossRef
[13]
go back to reference C. Schilling, J. dos Santos, Method and device for joining at least two adjoining work pieces by friction welding, US6722556B2, USA, 2004. C. Schilling, J. dos Santos, Method and device for joining at least two adjoining work pieces by friction welding, US6722556B2, USA, 2004.
[14]
[15]
go back to reference Y. Zuo, L. Kong, Z. Liu, Z. Lv, H. Wen, Trans. Indian Inst. Met. 73 (2020) 2975–2984.CrossRef Y. Zuo, L. Kong, Z. Liu, Z. Lv, H. Wen, Trans. Indian Inst. Met. 73 (2020) 2975–2984.CrossRef
[16]
go back to reference M.D. Tier, T.S. Rosendo, J.F. dos Santos, N. Huber, J.A. Mazzaferro, C.P. Mazzaferro, T.R. Strohaecker, J. Mater. Process. Technol. 213 (2013) 997–1005.CrossRef M.D. Tier, T.S. Rosendo, J.F. dos Santos, N. Huber, J.A. Mazzaferro, C.P. Mazzaferro, T.R. Strohaecker, J. Mater. Process. Technol. 213 (2013) 997–1005.CrossRef
[18]
[19]
go back to reference A.M. Nasiri, Z. Shen, J.S.C. Hou, A.P. Gerlich, Eng. Fail. Anal. 84 (2018) 25–33.CrossRef A.M. Nasiri, Z. Shen, J.S.C. Hou, A.P. Gerlich, Eng. Fail. Anal. 84 (2018) 25–33.CrossRef
[20]
go back to reference Z. Shen, Y. Ding, O. Gopkalo, B. Diak, A.P. Gerlich, J. Mater. Process. Technol. 252 (2018) 751–759.CrossRef Z. Shen, Y. Ding, O. Gopkalo, B. Diak, A.P. Gerlich, J. Mater. Process. Technol. 252 (2018) 751–759.CrossRef
[21]
go back to reference S. Ji, Y. Wang, Z. Li, Y. Yue, P. Chai, Trans. Indian Inst. Met. 70 (2017) 1417–1430.CrossRef S. Ji, Y. Wang, Z. Li, Y. Yue, P. Chai, Trans. Indian Inst. Met. 70 (2017) 1417–1430.CrossRef
[22]
go back to reference Z. Xu, Z. Li, S. Ji, L. Zhang, J. Mater. Sci. Technol. 34 (2018) 878–885.CrossRef Z. Xu, Z. Li, S. Ji, L. Zhang, J. Mater. Sci. Technol. 34 (2018) 878–885.CrossRef
[23]
go back to reference C.C. de Castro, A.H. Plaine, N.G. de Alcântara, J.F. dos Santos, Int. J. Adv. Manuf. Technol. 99 (2018) 1927–1936.CrossRef C.C. de Castro, A.H. Plaine, N.G. de Alcântara, J.F. dos Santos, Int. J. Adv. Manuf. Technol. 99 (2018) 1927–1936.CrossRef
[24]
go back to reference C. Zhang, J. Cao, A.A. Shirzadi, Sci. Technol. Weld. Join. 26 (2021) 236–243.CrossRef C. Zhang, J. Cao, A.A. Shirzadi, Sci. Technol. Weld. Join. 26 (2021) 236–243.CrossRef
[25]
go back to reference H.F. Zhang, L. Zhou, W.L. Li, G.H. Li, Y.T. Tang, N. Guo, J.C. Feng, Int. J. Miner. Metall. Mater. 28 (2021) 699–709.CrossRef H.F. Zhang, L. Zhou, W.L. Li, G.H. Li, Y.T. Tang, N. Guo, J.C. Feng, Int. J. Miner. Metall. Mater. 28 (2021) 699–709.CrossRef
[26]
go back to reference B. Fu, J. Shen, U.F.H.R. Suhuddin, T. Chen, J.F. dos Santos, B. Klusemann, M. Rethmeier, Scripta Mater. 203 (2021) 114113.CrossRef B. Fu, J. Shen, U.F.H.R. Suhuddin, T. Chen, J.F. dos Santos, B. Klusemann, M. Rethmeier, Scripta Mater. 203 (2021) 114113.CrossRef
[27]
go back to reference P. Li, S. Chen, H. Dong, H. Ji, Y. Li, X. Guo, G. Yang, X. Zhang, X. Han, J. Manuf. Process. 49 (2020) 385–396.CrossRef P. Li, S. Chen, H. Dong, H. Ji, Y. Li, X. Guo, G. Yang, X. Zhang, X. Han, J. Manuf. Process. 49 (2020) 385–396.CrossRef
[28]
[29]
go back to reference Z. Shen, Y. Ding, W. Guo, W. Hou, X. Liu, H. Chen, F. Liu, W. Li, A. Gerlich, Chin. J. Mech. Eng. 34 (2021) 75.CrossRef Z. Shen, Y. Ding, W. Guo, W. Hou, X. Liu, H. Chen, F. Liu, W. Li, A. Gerlich, Chin. J. Mech. Eng. 34 (2021) 75.CrossRef
[30]
go back to reference M.E.B. Cardillo, J. Shen, N.G. de Alcântara, C.R.M. Afonso, J.F. dos Santos, Weld. World 63 (2019) 33–41.CrossRef M.E.B. Cardillo, J. Shen, N.G. de Alcântara, C.R.M. Afonso, J.F. dos Santos, Weld. World 63 (2019) 33–41.CrossRef
[31]
go back to reference P. Chai, W. Hu, S. Ji, X. Ai, Z. Lv, Q. Song, J. Mater. Eng. Perform. 28 (2019) 6174–6181.CrossRef P. Chai, W. Hu, S. Ji, X. Ai, Z. Lv, Q. Song, J. Mater. Eng. Perform. 28 (2019) 6174–6181.CrossRef
[32]
go back to reference U. Suhuddin, V. Fischer, F. Kroeff, J.F. dos Santos, Mater. Sci. Eng. A 590 (2014) 384–389.CrossRef U. Suhuddin, V. Fischer, F. Kroeff, J.F. dos Santos, Mater. Sci. Eng. A 590 (2014) 384–389.CrossRef
[33]
go back to reference L. Zhou, L.Y. Luo, T.P. Zhang, W.X. He, Y.X. Huang, J.C. Feng, Int. J. Adv. Manuf. Technol. 92 (2017) 3425–3433.CrossRef L. Zhou, L.Y. Luo, T.P. Zhang, W.X. He, Y.X. Huang, J.C. Feng, Int. J. Adv. Manuf. Technol. 92 (2017) 3425–3433.CrossRef
[34]
go back to reference X.S. Feng, S.B. Li, L.N. Tang, H.M. Wang, Acta Metall. Sin. (Engl. Lett.) 33 (2020) 30–42.CrossRef X.S. Feng, S.B. Li, L.N. Tang, H.M. Wang, Acta Metall. Sin. (Engl. Lett.) 33 (2020) 30–42.CrossRef
[35]
go back to reference D. Zhang, J. Dong, J. Xiong, N. Jiang, J. Li, W. Guo, J. Mater. Res. Technol. 20 (2022) 1302–1314.CrossRef D. Zhang, J. Dong, J. Xiong, N. Jiang, J. Li, W. Guo, J. Mater. Res. Technol. 20 (2022) 1302–1314.CrossRef
[36]
go back to reference G. Li, L. Zhou, L. Luo, X. Wu, N. Guo, J. Mater. Res. Technol. 8 (2019) 4115–4129.CrossRef G. Li, L. Zhou, L. Luo, X. Wu, N. Guo, J. Mater. Res. Technol. 8 (2019) 4115–4129.CrossRef
[37]
go back to reference G.H. Li, L. Zhou, L.Y. Luo, X.M. Wu, N. Guo, Int. J. Miner. Metall. Mater. 28 (2021) 131–141.CrossRef G.H. Li, L. Zhou, L.Y. Luo, X.M. Wu, N. Guo, Int. J. Miner. Metall. Mater. 28 (2021) 131–141.CrossRef
[38]
go back to reference Z. Shen, W.Y. Li, Y. Ding, W. Hou, X.C. Liu, W. Guo, H.Y. Chen, X. Liu, J. Yang, A.P. Gerlich, J. Manuf. Process. 49 (2020) 260–270.CrossRef Z. Shen, W.Y. Li, Y. Ding, W. Hou, X.C. Liu, W. Guo, H.Y. Chen, X. Liu, J. Yang, A.P. Gerlich, J. Manuf. Process. 49 (2020) 260–270.CrossRef
[39]
go back to reference J. Shen, S.B.M. Lage, U.F.H. Suhuddin, C. Bolfarini, J.F. dos Santos, Metall. Mater. Trans. A 49 (2018) 241–254.CrossRef J. Shen, S.B.M. Lage, U.F.H. Suhuddin, C. Bolfarini, J.F. dos Santos, Metall. Mater. Trans. A 49 (2018) 241–254.CrossRef
[40]
go back to reference G. Zhang, W. Su, J. Zhang, Z. Wei, Metall. Mater. Trans. A 42 (2011) 2850–2861.CrossRef G. Zhang, W. Su, J. Zhang, Z. Wei, Metall. Mater. Trans. A 42 (2011) 2850–2861.CrossRef
[41]
[42]
[43]
[44]
go back to reference X.W. Feng, J.X. Li, Z.B. Zheng, B. Feng, H.K. Yang, J. Iron Steel Res. Int. 30 (2023) 1888–1895.CrossRef X.W. Feng, J.X. Li, Z.B. Zheng, B. Feng, H.K. Yang, J. Iron Steel Res. Int. 30 (2023) 1888–1895.CrossRef
[45]
go back to reference C. Zhang, G. Huang, Y. Cao, Q. Li, Y. Zhu, X. Huang, Q. Liu, J. Mater. Sci. 55 (2020) 15005–15032.CrossRef C. Zhang, G. Huang, Y. Cao, Q. Li, Y. Zhu, X. Huang, Q. Liu, J. Mater. Sci. 55 (2020) 15005–15032.CrossRef
[46]
go back to reference B.H. Silva, G. Zepon, C. Bolfarini, J.F. dos Santos, Mater. Sci. Eng. A 773 (2020) 138724.CrossRef B.H. Silva, G. Zepon, C. Bolfarini, J.F. dos Santos, Mater. Sci. Eng. A 773 (2020) 138724.CrossRef
[47]
go back to reference Z. Li, S. Ji, Y. Ma, P. Chai, Y. Yue, S. Gao, Int. J. Adv. Manuf. Technol. 86 (2016) 1925–1932.CrossRef Z. Li, S. Ji, Y. Ma, P. Chai, Y. Yue, S. Gao, Int. J. Adv. Manuf. Technol. 86 (2016) 1925–1932.CrossRef
[48]
go back to reference Z. Shen, Y. Ding, J. Chen, A.P. Gerlich, Int. J. Fatigue 92 (2016) 78–86.CrossRef Z. Shen, Y. Ding, J. Chen, A.P. Gerlich, Int. J. Fatigue 92 (2016) 78–86.CrossRef
[49]
go back to reference X.G. Zhu, L.F. Wang, F.B. Qiao, L.J. Guo, Trans. China Weld. Inst. 35 (2014) 91–94. X.G. Zhu, L.F. Wang, F.B. Qiao, L.J. Guo, Trans. China Weld. Inst. 35 (2014) 91–94.
[50]
go back to reference S. Venukumar, S.G. Yalagi, S. Muthukumaran, S.V. Kailas, Sci. Technol. Weld. Join. 19 (2014) 214–223.CrossRef S. Venukumar, S.G. Yalagi, S. Muthukumaran, S.V. Kailas, Sci. Technol. Weld. Join. 19 (2014) 214–223.CrossRef
[51]
go back to reference R.C. Brzostek, U. Suhuddin, J.F. dos Santos, Fatigue Fract. Eng. Mater. Struct. 41 (2018) 1208–1223.CrossRef R.C. Brzostek, U. Suhuddin, J.F. dos Santos, Fatigue Fract. Eng. Mater. Struct. 41 (2018) 1208–1223.CrossRef
[52]
go back to reference H. Yang, D. Cai, J. Li, C.Y. Kwok, Y. Zhao, Y. Li, H. Liu, W. Lai, Fatigue Fract. Eng. Mater. Struct. 44 (2021) 3219–3223.CrossRef H. Yang, D. Cai, J. Li, C.Y. Kwok, Y. Zhao, Y. Li, H. Liu, W. Lai, Fatigue Fract. Eng. Mater. Struct. 44 (2021) 3219–3223.CrossRef
[53]
go back to reference G.S. Vacchi, R. Silva, A.H. Plaine, U.F.H. Suhuddin, N.G. Alcântara, V.L. Sordi, C.A.D. Rovere, Mater. Today Commun. 22 (2020) 100759.CrossRef G.S. Vacchi, R. Silva, A.H. Plaine, U.F.H. Suhuddin, N.G. Alcântara, V.L. Sordi, C.A.D. Rovere, Mater. Today Commun. 22 (2020) 100759.CrossRef
[54]
go back to reference Y. Zou, W. Li, Y. Xu, X. Yang, Q. Chu, Z. Shen, Mater. Charact. 183 (2022) 111594.CrossRef Y. Zou, W. Li, Y. Xu, X. Yang, Q. Chu, Z. Shen, Mater. Charact. 183 (2022) 111594.CrossRef
[55]
go back to reference Y.X. Qiao, Z.B. Zheng, H.K. Yang, J. Long, P.X. Han, J. Iron Steel Res. Int. 30 (2023) 1463–1476.CrossRef Y.X. Qiao, Z.B. Zheng, H.K. Yang, J. Long, P.X. Han, J. Iron Steel Res. Int. 30 (2023) 1463–1476.CrossRef
[56]
go back to reference Z.B. Zheng, H.K. Yang, A.P. Shatrava, J. Long, Y.H. Wang, J.X. Li, K.H. Zheng, Mater. Sci. Eng. A 862 (2023) 144467.CrossRef Z.B. Zheng, H.K. Yang, A.P. Shatrava, J. Long, Y.H. Wang, J.X. Li, K.H. Zheng, Mater. Sci. Eng. A 862 (2023) 144467.CrossRef
[57]
[58]
go back to reference H. Li, X.S. Liu, Y. Zhang, T. Yuan, E. Hodúlová, B. Šimeková, M. Bober, J. Senkara, Z.X. Li, Weld. World 66 (2022) 923–933.CrossRef H. Li, X.S. Liu, Y. Zhang, T. Yuan, E. Hodúlová, B. Šimeková, M. Bober, J. Senkara, Z.X. Li, Weld. World 66 (2022) 923–933.CrossRef
[59]
go back to reference A.N. Ashong, M. Lee, S.T. Hong, Y.S. Lee, J.H. Kim, Met. Mater. Int. 27 (2021) 639–649.CrossRef A.N. Ashong, M. Lee, S.T. Hong, Y.S. Lee, J.H. Kim, Met. Mater. Int. 27 (2021) 639–649.CrossRef
[60]
go back to reference Y. Zhao, H. Yang, D. Cai, A. Andrii, J. Li, X. Chen, J. Adhes. Sci. Technol. (2023) 1–12.CrossRef Y. Zhao, H. Yang, D. Cai, A. Andrii, J. Li, X. Chen, J. Adhes. Sci. Technol. (2023) 1–12.CrossRef
[61]
go back to reference S. Hu, Z. Sun, F. Shen, J. Deng, W. Yang, H. Yang, J. Wuhan Univ. Technol. Mater. Sci. Ed. 39 (2024) 167–173. S. Hu, Z. Sun, F. Shen, J. Deng, W. Yang, H. Yang, J. Wuhan Univ. Technol. Mater. Sci. Ed. 39 (2024) 167–173.
[62]
go back to reference A. Derlatka, Zeszyty Naukowe Politechniki Częstochowskiej Budownictwo 177 (2021) 30–36.CrossRef A. Derlatka, Zeszyty Naukowe Politechniki Częstochowskiej Budownictwo 177 (2021) 30–36.CrossRef
[63]
go back to reference A. Fawcett, X. Chen, X. Huang, C. Li, Compos. Part B Eng. 161 (2019) 96–106.CrossRef A. Fawcett, X. Chen, X. Huang, C. Li, Compos. Part B Eng. 161 (2019) 96–106.CrossRef
[64]
[65]
[66]
go back to reference C. Leng, H. Yang, G. Yi, H. Lo, J. Li, Y. Li, Mater. Sci. Eng. Technol. 55 (2024) 7–14. C. Leng, H. Yang, G. Yi, H. Lo, J. Li, Y. Li, Mater. Sci. Eng. Technol. 55 (2024) 7–14.
Metadata
Title
Refill friction stir spot welding (RFSSW): a review of processing, similar/dissimilar materials joining, mechanical properties and fracture mechanism
Authors
Yun-qiang Zhao
Hao-kun Yang
Aloshyn Andriia
Hong-hang Lo
Jia-xin Li
Publication date
12-04-2024
Publisher
Springer Nature Singapore
Published in
Journal of Iron and Steel Research International
Print ISSN: 1006-706X
Electronic ISSN: 2210-3988
DOI
https://doi.org/10.1007/s42243-024-01209-2

Premium Partners