ARTICLE IN PRESS

International Journal of Machine Tools & Manufacture 47 (2007) 2230–2236

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Effect of tool geometry on microstructure and static strength in friction

stir spot welded aluminium alloys
Yasunari Tozakia, Yoshihiko Uematsub,, Keiro Tokajib
a
Gifu Prefectural Research Institute for Machinery and Material, 1288 Oze, Seki 501-3265, Japan
b
Department of Mechanical and Systems Engineering, Gifu University, 1-1 Yanagido, Gifu 501-1193, Japan
Received 16 June 2006; accepted 2 July 2007
Available online 31 July 2007

Abstract

The effect of tool geometry on microstructure and static strength in friction stir spot welds of 6061 aluminium alloy sheets was studied.
Tools with three different probe lengths were used to join the aluminium sheet with different tool rotational speeds and tool holding
times. The weld microstructures varied significantly depending on probe length, tool rotational speed and tool holding time. Two
particular aspects were identified: the thickness of the upper sheet under the shoulder indentation and the nugget size. The former
decreased with increasing probe length at the shortest tool holding time and the slowest tool rotational speed, but there were no
discernible differences in other welding conditions, while the latter increased with increasing probe length, tool rotational speed and tool
holding time. The tensile shear strength increased with increasing probe length, while the cross-tension strength was not affected
significantly by probe length. Two fracture modes were observed: shear fracture of the nugget and mixed mode fracture under tensile
shear loading, and nugget debonding and pull-out under cross-tension loading. Based on experimental observation of the
microstructures, the effect of probe length on static strength and the fracture mechanisms were discussed.
r 2007 Elsevier Ltd. All rights reserved.

Keywords: Friction stir spot welding; Static strength; Microstructure; Probe length; Fracture mode

1. Introduction the FSSW process, thus a systematic study has to be done

Recently, a new joining technique called friction stir spot
welding (FSSW) or friction spot joining (FSJ) has been
developed [1–3]. This technique has the same advantages as
friction stir welding (FSW) such as solid-state process, ease
of handling, joining of dissimilar materials and materials
that are difficult to fusion weld, low distortion, excellent
mechanical properties and little waste or pollution. Hence,
it is expected to apply for joining of lightweight materials in
order to achieve high performance and energy and cost
saving of machines and structures.
When FSSW is applied to joining of load-bearing
components, the strength of welds becomes critical.
However, since FSSW is a rather newly developed
technology, the optimum welding condition has not yet
been established. There are many processing parameters in
Corresponding author. Tel.: +81 58 293 2501; fax: +81 58 230 1892.
E-mail address: yuematsu@gifu-u.ac.jp (Y. Uematsu).
in order to understand the effect of individual parameter
on the microstructure and mechanical properties of welds
[3–5].
In a previous report [6], the authors indicated the effects
of tool rotational speed and tool holding time on static
strength of friction stir spot welds, where the tool geometry
was fixed. Tool geometry such as probe length, probe shape
and shoulder size is also a key parameter, because it would
affect the heat generation and the plastic material flow.
A few studies on the effect of tool geometry have been
reported on FSW [7,8], but there have been very limited
studies on FSSW [4].
In this study, FSSW was performed to join 6061-T4
aluminium alloy sheets using tools with three different
probe lengths. The microstructures of welds were first
characterized based on experimental observations of the
cross-section. Tensile shear tests and cross-tension tests
were then carried out and the effect of probe length on
static strength and the fracture mechanisms were discussed.

0890-6955/$ - see front matter r 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2007.07.005
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Y. Tozaki et al. / International Journal of Machine Tools & Manufacture 47 (2007) 2230–2236 2231

2. Experimental details 10 mm. All probes, made of high-speed steel (Japanese

The materials used are two different 6061-T4 aluminium
alloy sheets with 2 mm thickness. Their chemical composi-
tions are listed in Table 1. For microstructure character-
ization, 6061-T4(A) and 6061-T4(B) were employed as the
upper and lower sheets to make friction spot stir welds,
respectively, because observation of material flow becomes
easier with a different extent of etching due to different Cu
contents (see Table 1). For evaluation of static strengths,
6061-T4(A) was employed as the upper and lower sheets of
welds.
Fig. 1 shows a schematic illustration of the tool
geometries with different probe lengths. As can be seen in
the figure, three different probe lengths of 3.7, 3.1 and
2.4 mm were evaluated under a given shoulder diameter of
Industrial Standard (JIS), SKD61), had a standard metric
M3.5 left-hand thread.
The welding machine operated under position control
mode was used. In all cases, a constant tool plunge rate of
20 mm/min and a shoulder plunge depth of 0.2 mm below
the upper plate surface were applied. The tool rotational
speeds and the tool holding times were also varied, which
were 2000, 2500 and 3000 rpm, and 0.2, 1 and 3 s,
respectively.
Fig. 2 illustrates the configuration of lap-shear and cross-
tension specimens employed. Both specimens were made by
using two 40 mm  150 mm sheets with a 40 mm  40 mm
overlap area. Tensile shear tests and cross-tension tests
were performed according to JIS Z3136 and JIS Z3137,
respectively.

Table 1 3. Results and discussion

Chemical compositions of materials (wt%)

Alloy Mg Si Cu Fe Mn Cr Zn Ti
3.1. Microstructure characterization of welds

6061-T4(A) 0.6 1 o0.2 0.05 o0.05 0.3 o0.05 The microstructures of the cross-section of welds at the
6061-T4(B) 1.0 0.63 0.27 0.29 0.07 0.17 0.01 0.02 tool rotational speeds of 2000 and 3000 rpm are shown in
Figs. 3 and 4, respectively. It can be seen that the
microstructures of welds vary significantly depending on
probe length, tool rotational speed and tool holding time.

=10mm
=10mm
=10mm A noticeable point in the microstructures is the upward
material flow of the lower sheet during the FSSW process.
The amount of the lower sheet that flows upward increases
with increasing probe length regardless of tool rotational
speed and tool holding time. It can also be seen that under
a given probe length, the upward material flow of the lower
sheet is more remarkable with increasing tool rotational
lp=3.7mm lp=3.1mm lp=2.4mm
speed and tool holding time. This is the same tendency as
the results observed in a previous report in which the
0.2mm 0.2mm 0.2mm
effects of tool rotational speed and tool holding time on
the weld microstructure were evaluated [6]. As a result of
Upper sheet the upward movement of the lower sheet, the thickness of
the upper sheet under the shoulder indentation, denoted as
Lower sheet tu in Fig. 3, decreases with increasing probe length at the
tool holding time of 0.2 s and the tool rotational speed of
Fig. 1. Geometry of tools employed. 2000 rpm and with increasing tool holding time at a given

40 t=2 40 t=2
Spot weld Spot weld
100
40

40

150 150

Fig. 2. Configuration of test specimens (in mm).

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Fig. 3. Microstructures of the cross-section of friction stir spot welds for different probe lengths and tool holding times at a tool rotational speed of
2000 rpm.

Fig. 4. Microstructures of the cross-section of friction stir spot welds for different probe lengths and tool holding times at a tool rotational speed of
3000 rpm.

probe length, but there are no discernible differences at
longer tool holding times or faster tool rotational speeds.
It should also be noted that the distance, dn, in the
microstructures (also marked in Fig. 3), corresponding to
the actual nugget size, is significantly affected by probe
length, tool rotational speed and tool holding time. The dn
size increases with increasing probe length and also
increases with increasing tool rotational speed and tool
holding time under a given probe length [6].
3.2. Tensile shear strength
The relationships between tensile shear force, Fs, and
tool holding time, t, are represented in Fig. 5 for different
tool rotational speeds. It can be seen that the tensile shear
strength increases with increasing probe length at all the
tool rotational speeds studied. With a few exceptions, it
tends to increase with increasing tool holding time and tool
rotational speed under a given probe length [6], but the
dependence of tensile shear strength on tool holding time
becomes less remarkable with increasing tool rotational
speed. For example, the tensile shear strengths for the
probe lengths of 3.1 and 3.7 mm are independent of tool
holding time at the tool rotational speed of 3000 rpm.
Furthermore, it can be seen that differences in tensile shear
strength among three probe lengths become small with
increasing tool rotational speed.
3.3. Cross-tension strength
Cross-tension force, Fc, is shown in Fig. 6 as a function
of tool holding time for different tool rotational speeds. At
a given tool rotational speed, the probe length of 3.1 mm
tends to have the minimum cross-tension strength regard-
less of tool holding time, but differences in cross-tension
strength among three probe lengths are rather small,
particularly at faster tool rotational speeds. It can also
be seen that the cross-tension strength decreases with
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6 6
6061–T4 FSSW 6061–T4 FSSW
Tool rotational speed: 2000 rpm Tool rotational speed:
5 Probe length
Tensile shear force Fs (kN)
5

Tensile shear force Fs (kN)

Probe length 2500 rpm
2.4 mm 2.4 mm
3.1 mm
3.1 mm
4 3.7 mm 4 3.7 mm

3 3

2 2
Open: shear fracture Open: shear fracture
1 Solid: mixed fracture 1 Solid: mixed fracture

0 1 2 3 4 0 1 2 3 4
Tool holding time t (sec) Tool holding time t (sec)

6
6061–T4 FSSW Probe length
Tool rotational speed:
Tensile shear force Fs (kN)

5 3000 rpm
2.4 mm
3.1 mm
3.7 mm
4

2
Open: shear fracture
Solid: mixed fracture
1

0 1 2 3 4
Tool holding time t (sec)

Fig. 5. Tensile shear force as a function of tool holding time: (a) 2000 rpm, (b) 2500 rpm, (c) 3000 rpm.

increasing tool rotational speed and tool holding time [6], Fig. 7(b). Fig. 7(c) shows the top view of the upper and
except for only the case of the tool rotational speed of lower sheets, from which the probe indentation can be
2000 rpm and the tool holding time of 0.2 s. clearly recognized without any deformation or damage. An
example of tensile/shear mixed fracture is represented in
3.4. Fracture modes under tensile shear and cross-tension Fig. 8 for the welding condition of the probe length of
loading 3.7 mm, the tool rotational speed of 3000 rpm and the tool
holding time of 3 s. As seen in the cross-section of a
Two different fracture modes were observed under partially loaded weld in Fig. 8(a), tensile fracture first
tensile shear loading: shear fracture and tensile/shear occurred at the position with thinner thickness of the upper
mixed fracture, which are indicated for individual data sheet under the shoulder indentation, then propagated
point in Fig. 5. In case of the probe length of 2.4 mm, shear along the circumferential direction (Fig. 8(c)) and shear
fracture occurred independent of tool holding time at the fracture finally took place as seen in Fig. 8(b). Similar
tool rotational speed of 2000 rpm, while tensile/shear mixed fracture modes under tensile shear loading have been
fracture took place only at a longer tool holding time of 3 s observed by Fujimoto et al. [3] and Lin et al. [4,5].
at the tool rotational speeds of 2500 and 3000 rpm. As the Two typical fracture modes were also seen under cross-
probe length increases, mixed fracture becomes the tension loading: nugget debonding and pull-out, which are
dominant mechanism with increasing tool rotational speed indicated in Fig. 6. Nugget debonding only occurred at the
and tool holding time. welding condition of the probe length of 2.4 mm, the tool
Fig. 7 reveals an example of shear fracture for the rotational speed of 2000 rpm and the tool holding time of
welding condition of the probe length of 3.7 mm, the tool 0.2 s (see Fig. 6(a)), while in all other welding conditions,
rotational speed of 2500 rpm and the tool holding time of pull-out took place.
0.2 s. The cross-section of a partially loaded weld is shown Debonding fracture is revealed in Fig. 9, showing that
in Fig. 7(a). It can be seen that the faying surface between the faying surface between the upper and lower sheets was
the upper and lower sheets is almost sheared off, then torn off. An example of pull-out fracture is shown in
resulting in complete shear fracture of the nugget as seen in Fig. 10 for the welding condition of the probe length of
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6 6
6061–T4 FSSW 6061–T4 FSSW
Tool rotational speed: 2000 rpm Tool rotational speed: 2500 rpm
Cross tension force Fc (kN)

Cross tension force Fc (kN)

5 Probe length 5 Probe length
2.4 mm 2.4 mm
3.1 mm 3.1 mm
4 3.7 mm 4 3.7 mm
Fracture mode:
Open: debonding Fracture mode: pull–out
3 Solid: pull–out 3

2 2

1 1

0 1 2 3 4 0 1 2 3 4
Tool holding time t (sec) Tool holding time t (sec)

6
6061–T4 FSSW
Tool rotational speed: 3000 rpm
5
Cross tension force Fc (kN)

Probe length
2.4 mm
3.1 mm
4 3.7 mm

Fracture mode: pull–out

3

0 1 2 3 4
Tool holding time t (sec)

Fig. 6. Cross-tension force as a function of tool holding time: (a) 2000 rpm, (b) 2500 rpm, (c) 3000 rpm.

3.1 mm, the tool rotational speed of 2500 rpm and the tool
holding time of 0.2 s. Pull-out occurred along the
circumference of the thinner thickness position of the
upper sheet under the shoulder indentation.

4. Discussion

4.1. Microstructural factors controlling static strength and

fracture mode

As seen in Figs. 3 and 4, the weld microstructures varied

significantly depending on probe length, tool rotational
speed and tool holding time. Two particular aspects were
identified. One was the thickness of the upper sheet under
the shoulder indentation, tu. As the probe length increases,
the materials may be stirred severely and extensively and
thus the lower sheet moves upward. Consequently, the
thickness of the upper sheet decreases. This was clearly
observed at the welding condition of the tool holding time
Fig. 7. Shear fracture of nugget observed at welding condition of probe
of 0.2 s and the tool rotational speed of 2000 rpm. When
length of 3.7 mm, tool rotational speed of 2500 rpm and tool holding time
of 0.2 s under tensile shear loading: (a) cross-section of a partially loaded the tool rotational speed or the tool holding time increases,
weld, (b) cross-section after failure, (c) top view of upper and lower sheets. the upward material flow of the lower sheet would become
The arrows indicate the loading direction. more remarkable due to severe stirring regardless of probe
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Y. Tozaki et al. / International Journal of Machine Tools & Manufacture 47 (2007) 2230–2236
Fig. 8. Tensile/shear mixed fracture observed at welding condition of
probe length of 3.7 mm, tool rotational speed of 3000 rpm and tool
holding time of 3.0 s under cross-tension loading: (a) cross-section of a
partially loaded weld, (b) cross-section after failure, (c) top view of upper
and lower sheets. The arrows indicate the loading direction.
Fig. 9. Debonding of the nugget observed under cross-tension loading
(probe length: 2.4 mm, tool rotational speed: 2000 rpm, tool holding time:
0.2 s). The arrows indicate the loading direction.
length, thus differences in the tu size became less
discernible. The other microstructural aspect was the
distance, dn, corresponding to the actual nugget size, which
increased with increasing probe length, tool rotational
speed and tool holding time, because the increase of these
processing parameters would result in more extensive
stirring or sufficient heat input during the FSSW process.
It is believed that the above microstructural factors play
a dominant role in controlling the static strength and the
2235
Fig. 10. Pull-out of the nugget observed under cross-tension loading
(probe length: 3.1 mm, tool rotational speed: 2500 rpm, tool holding time:
0.2 s). The arrows indicate the loading direction.
fracture mechanisms of friction stir spot welds, because
fracture observed under both tensile shear loading and
cross-tension loading took place depending on the relative
size of both microstructural factors.
4.2. Probe length dependence of static strength
The tensile shear strength increased with increasing
probe length regardless of tool rotational speed and tool
holding time (Fig. 5), which is attributed to the dn size.
When the probe length is short, i.e. 2.4 mm, the dn size is
relatively small because of low heat input, particularly
remarkable at slower tool rotational speeds and shorter
tool holding times. Therefore, shear fracture of the nugget
takes place easily, leading to lower tensile shear strength.
On the contrary, when the probe length is long, i.e. 3.7 mm,
the dn size is relatively large, this resulting in higher tensile
shear strength. However, the tu size becomes adversely
small, thus fracture first occurs at the position with thinner
thickness of the upper sheet under the shoulder indenta-
tion, then propagates along the circumferential direction
and finally shear fracture takes place due to decease in the
area effectively supported tensile load (Fig. 8).
As seen in Fig. 6, the dependence of the cross-tension
strength on probe length was obscure regardless of tool
rotational speed and tool holding time. Debonding fracture
of the nugget only occurred under the welding condition of
the probe length of 2.4 mm, the tool rotational speed of
2000 rpm and the tool holding time of 0.2 s. This is because
the bonding strength of the nugget was low due to low heat
input, resulting in very low cross-tension strength. Under
all other welding conditions, the cross-tension strength is
believed to be dependent on the tu size, because fracture
mode observed was pull-out at the thinner thickness
position of the upper sheet under the shoulder indentation.
However, differences in the tu size were very small among
three probe lengths (Figs. 3 and 4), this making the
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2236 Y. Tozaki et al. / International Journal of Machine Tools & Manufacture 47 (2007) 2230–2236
dependence of the cross-tension strength on probe length
unclear.
4.3. Effects of tool rotational speed and tool holding time on
static strength
The authors have investigated the effects of tool
rotational speed and tool holding time on static strength
of friction stir spot welds and indicated that the tensile
shear strength increased with decreasing tool rotational
speed and increasing tool holding time, while the cross-
tension strength decreased with increasing tool rotational
speed and tool holding time [6]. The same dependence of
both static strengths on tool holding time was observed in
the present study. This can also be realized in terms of both
microstructural factors, i.e. the dn and tu sizes. As described
previously, the dn size increased with increasing tool
rotational speed and tool holding time. Under tensile shear
loading, the increase in the dn size results in the increase in
the tensile shear strength because of increased effective
area. As a result, fracture first occurs at the position with
thinner thickness of the upper sheet under the shoulder
indentation.
The cross-tension strength decreased with increasing tool
rotational speed and tool holding time, but the dependence
of the cross-tension strength on tool holding time became
less remarkable with increasing tool rotational speed.
When the tool rotational speed or the tool holding time
increased, differences in the tu size became less discernible,
but slight differences in the tu size would contribute the
observed dependence of the cross-tension strength on tool
rotational speed and tool holding time, because pull-out
fracture inevitably occurred at the thinner thickness
position of the upper sheet.
Only the difference in the results between the previous
report [6] and the present study is the dependence of tensile
shear strength on tool rotational speed. With increasing
tool rotational speed, the tensile shear strength decreased
in the previous report, while increased in the present study.
This may be attributed to the dn size that decreased in the
previous report, while increased in the present study, with
increasing tool rotational speed. Further studies are needed
to understand such the discrepancy.
5. Conclusions
1. The microstructures of welds varied significantly de-
pending on probe length, tool rotational speed and tool
holding time. Two particular aspects were identified: the
thickness of the upper sheet under the shoulder
indentation and the actual nugget size. The former
decreased with increasing probe length only at the
shortest tool holding time and the slowest tool
rotational speed, but it was nearly the same in other
welding conditions, while the latter increased with
increasing probe length, tool rotational speed and tool
holding time.
2. The tensile shear strength increased with increasing
probe length, while the cross-tension strength was not
affected significantly by probe length. This dependence
of static strength on probe length was well realized in
terms of both the thickness of the upper sheet under the
shoulder indentation and the nugget size.
3. Two different fracture modes were observed under both
tensile shear loading and cross-tension loading: shear
fracture of the nugget and tensile/shear mixed fracture
under tensile shear loading, and nugget debonding and
pull-out under cross-tension loading. The occurrence of
these fracture modes was related to both the thickness of
the upper sheet under the shoulder indentation and the
nugget size.
4. With increasing tool rotational speed and tool holding
time, the tensile shear strength increased, while the
cross-tension strength decreased.
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