Hybrid joining of cast aluminum and sheet steel using refill friction stir spot welding with strength enhancement via adhesive application

Research output: Contributions to collected editions/worksArticle in conference proceedingsResearchpeer-review

Authors

  • Tong Shen
  • Rafael Piccoli
  • Leonardo Hendler
  • Andre Barbosa
  • Ting Chen
  • Uceu Suhuddin
  • Massimo Cucco
  • Benjamin Klusemann

This study investigates the hybrid joining of cast aluminum AlSi10Mg and DP600 steel using refill friction stir spot welding (refill FSSW) integrated with adhesive application. Box Behnken Design (BBD) was employed for experimental design, enabling a detailed statistical investigation of the effects of process parameters on joint strength and macrostructure. The final correlations for predicting joint strength in both non-adhesive and adhesive-assisted configurations were obtained through regression analysis. Pre-clamping techniques, including clamping ring and full tool pre-clamp methods, were employed to improve adhesive squeezing. The results demonstrate that adhesive-assisted joints achieve significantly higher lap-shear strength, exceeding twice the strength of joints without adhesive. The findings contribute to advancing refill FSSW for multi-material applications, particularly in automotive structures.

Original languageEnglish
Title of host publication28th International ESAFORM Conference on Material Forming, ESAFORM 2025
EditorsPierpaolo Carlone, Luigino Filice, Domenico Umbrello
Number of pages10
PublisherAssociation of American Publishers
Publication date07.2025
Pages1469-1478
ISBN (print)9781644903599
DOIs
Publication statusPublished - 07.2025
Event28th International ESAFORM Conference on Material Forming, ESAFORM 2025 - Paestum, Italy
Duration: 07.05.202509.05.2025

Bibliographical note

Publisher Copyright:
© 2025, Association of American Publishers. All rights reserved.

    Research areas

  • Adhesive Application, Cast Aluminum, Dissimilar Welding, Refill Friction Stir Spot Welding
  • Engineering

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