Influence of FSSW parameters on fracture mechanisms of 5182 aluminium welds

The influence of the tool rotational speed, the probe plunge depth and the shoulder penetration depth on weld microstructure and on the weld strength have been studied. The shear tests showed that the friction stir spot welds fail by nugget pullout. Three microstructural factors play a determinant role on the weld's strength: the size and location of the stir zone, and the unwelded interface tip slope. With increasing rotational speed, the shear strength increases because of the larger size of the stir zone. By changing the probe plunge depth the location of the stir zone can be controlled in order to maximize the bonded distance between the interface tip and the central hole left by the probe. The shoulder penetration depth must be sufficient to ensure a horizontal interface tip and therefore avoid fracture by the opening mode (mode I) during shear loading.