Tool wear behaviour and the influence of wear-resistant coatings during refill friction stir spot welding of aluminium a
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RESEARCH PAPER
Tool wear behaviour and the influence of wear-resistant coatings during refill friction stir spot welding of aluminium alloys Dennis Lauterbach 1
&
Daniel Keil 2 & Alexander Harms 1 & Christoph Leupold 1 & Klaus Dilger 3
Received: 4 August 2020 / Accepted: 23 October 2020 # International Institute of Welding 2020
Abstract Numerous studies report a wide range of possible applications for refill friction stir spot welding, reaching from light metal alloys and cast materials to mixed construction applications. In order to make use of these potentials, it is necessary to enhance the tool concept with the aim to increase tool life. Previous studies have reported on different tool life quantities between 5 and 9000 spot welds. Thus, the aim of the present study was to analyse the tool wear and to derive and evaluate suitable measures to reduce it. Therefore, the general properties of the selected coating systems CrVN, WC and TiBN-TiB2 were determined and compared to a nitrided state. Welding tools were then provided with the respective layers and tested in the process. After 6400 spot welds, the wear on each tool was determined and compared to the others. The results were then related to the preliminary tests in order to assign an influence on the welding behaviour to the individual layer characteristics, e.g. hardness and adhesion strength. With the help of the investigated layers, overall improvements were achieved regarding the tool life, and at the same time, no relevant negative influence on the welding process was detected. Therefore, the described and in published studies proven potentials of the underlying process can be exploited and the process can be brought closer to the applicability in a series production. Keywords Refill friction stir spot welding . Tool wear . Wear-resistant coating . Series production . Aluminium
1 Introduction There are different studies on refill friction stir spot welding which prove the high potential of the process for a wide range of applications. In [1], the process was attributed with the possibility of selecting from the whole variety of aluminium alloys with different alloying elements and combining them freely. Other publications show, for example, investigations with EN AW 7475, EN AW 6061 or EN AW 5052 [2–8]. Additionally, Goushegir describes in [5], that RFSSW can be
Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process * Dennis Lauterbach [email protected] 1
Volkswagen AG, Group Innovation, Berliner Ring 2, 38440 Wolfsburg, Germany
2
Volkswagen AG, Technical Development Seat Structures, Berliner Ring 2, 38440 Wolfsburg, Germany
3
Institute of Joining and Welding, TU Braunschweig, Langer Kamp 8, 38106 Braunschweig, Germany
used to produce metal-polymer hybrid composites. However, the use of the process is restricted by the low tool life. Previous studies describe a high level of wear when welding different aluminium alloys. In [9], EN AW 5454 sheets with a thickness of 2.
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