Z. Feng, M. L. Santella, S. A. David, Oak Ridge National Laboratory, Oak Ridge, TN; T. Y. Pan, Ford Motor Company, Dearborn, MI

Summary:

Friction Stir Spot Welding (FSSW) is a novel derivative of the linear friction stir welding process. It has generated considerable interests in several industry sectors. In this paper, we will discuss our recent research and development related to this technology, particularly with the fixed pin approach, toward both Al alloys and high-strength steels. Observations on the material flow, interface movement, and possible bonding mechanisms will be presented. In addition, the weld joint strength and microstructures as function of process conditions will be described. Finally, the process speed and potential economic advantages of the process will be presented.