High Speed Refill Friction Stir Spot Welding
By Brigham Larsen (Brigham Young University), Yuri Hovanski (Brigham Young University), Arnold Wright (Brigham Young University)

Since the patent on refill friction stir spot welding (RFSSW) in 2004 was released significant development has been reported internationally. Globally, three machine manufacturers have produced robotic end-effectors capable of producing RFSSWs; however, the process has yet to really be accepted for large scale production. Three main impediments have hindered the advancement of the technology, namely: cycle-time, tool durability, and cost. As cost is largely a function of the first two, this work focuses on significant reductions in cycle time and the associated effects on tool durability. We report on the development of 500ms cycle times for automotive aluminum alloys along with the associated parameter – property relationships. Additionally, we evaluate the influence that cycle time reductions have on related weld process windows. Finally, we report on the impact of reducing cycle time on the tool life and durability.