Journal of Manufacturing Processes 41 (2019) 177–187

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Journal of Manufacturing Processes

journal homepage: www.elsevier.com/locate/manpro

Modified friction stir clinching with protuberance-keyhole levelling: A T

process for production of welds with high strength
Moslem Paidara, , Olatunji Oladimeji Ojob, Amirhossein Moghanianc, Amal Shaji Karapuzhad,
⁎

Akbar Heidarzadehe
a
Department of Material Engineering, South Tehran Branch, Islamic Azad University, Tehran 1459853849, Iran
b
Department of Industrial and Production Engineering, Federal University of Technology Akure, Nigeria
c
Department of Materials Engineering, Imam Khomeini International University, Qazvin 34149-16818, Iran
d
Applied Micro and Nanotechnology lab, Department of Mechanical and Aerospace Engineering, Monash University, Australia
e
Department of Materials Engineering, Azarbaijan Shahid Madani University, Tabriz, Iran

ARTICLE INFO ABSTRACT

Keywords: Modified friction stir clinching (MFSC) with protuberance-keyhole leveling approach is employed in joining
Modified friction stir clinching dissimilar AA2024-T3/AA7075-T6 Al alloys. This technique is a two-step approach where friction stir clinching
Mechanical properties is established in the first step while the inherent step-like (protuberance-keyhole cavity) is eliminated in the
Microstructure second step. The microstructure, mechanical properties and fracture mode of the MFSC joints are examined and
Fracture
compared with that of the conventional keyhole friction stir spot welds. The results reveal that the new approach
Aluminium alloys
eliminates the formation of hook defect while geometric-differential flow-induced defects are formed in the
joint. Protuberance and shoulder indentation refilling processes form flow-induced defects at the weld center
and at the circumferential shoulder edges respectively. The severity of these defects is reduced via better inter-
mixing and flowability at high tool rotational speed. Atomic diffusion induces the formation of Al2CuMg and
Mg2Si phases in the joints (stir zones). A rise in tool rotational speed increases the tensile-shear and cross-tension
loads of the joint from 6798 N to 9487 N and 4366 N to 6850 N respectively. The new joining process improved
the joint quality due to enhanced effective bonded/shear area as compared to that of the conventional keyhole
friction stir spot welded joint.

1. Introduction
Zhang et al. [1] reported that metal-interlocking and non-me-
tallurgical bonding in conventional clinched joints cause undesirable
clinched-zone pull-out failure at low external loads. There is thus a need
to improve on the conventional joining. Friction clinching is a new
concept of clinching that reduces joining force (by 40–60 times) and
crack formation while improving material flow and metallurgical
bonding in similar/dissimilar joints [2,3]. Improved fatigue strength of
clinched joints is attributed to the induced relaxation of stress con-
centration and large yield stress in metal sheets [4]. In fact, friction stir
clinching has been reported to be suitable for obtaining good strength
in anodized, Alclad and other surface-treated sheet metals [5].
Geometrical interlocking shape features (like undercut and neck
thickness) control the strength of clinched joints [6] while modification
of these properties is vital for joint strength improvement. Lee et al. [7]
revealed that a 50% decline in damage accumulation at the neck of the
joint was achieved via the use of spring die. The spring die enforced
sufficient hydrostatic compressive stress at the neck of the upper metal
sheet in order to prevent neck fracture or defect. Abe et al. [8] and Chen
et al. [9] developed a two-stage clinching process for metal sheet
joining and upsetting/reshaping of protrusion height (of the clinched
joint). This approach was reported to improve joint strength and joining
range for metal sheets with low flow stresses. The induced material flow
due to the upsetting process reduced protrusion height and increased
both energy absorption capability and strength of the joints [9]. Com-
plete elimination of protrusion in friction stir clinched joint is a pro-
spect that can improve the overall joint quality. Clinched joint protru-
sion is similar to the keyhole in friction stir spot welded joints. These
inherent defects (protrusions/keyholes) are areas with stress con-
centration and corrosion preferential sites because there will be diffi-
culty in getting body paint to reach the bottom of the protrusions/
keyholes. The notable approach for removing keyhole in literature is
refilled friction stir spot welding (RFSSW) having tool complexity

⁎
Corresponding author.
E-mail address: m.paidar@srbiau.ac.ir (M. Paidar).

https://doi.org/10.1016/j.jmapro.2019.03.030
Received 8 February 2019; Received in revised form 18 March 2019; Accepted 25 March 2019
1526-6125/ © 2019 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
M. Paidar, et al. Journal of Manufacturing Processes 41 (2019) 177–187

[10,11] and the use of pinless tool-assisted FSSW [12–14]. Table 2

Other novel approaches have been employed in eliminating pro- Chemical composition of base alloys (wt.%).
trusion/keyhole of friction stir assisted joints in literature. For instance, Alloy Al Mg Cu Mn Zn Cr
Enami et al. [15] investigated keyhole-less friction stir spot welding of
2024 aluminum alloy with and without alumina nanoparticles. The AA2024-T3 Base 1.28 4.9 0.629 0.142 0.0123
AA7075-T6 Base 2.3 1.6 0.16 5.3 0.17
process involves the creation of spot weld (with a concave tool
shoulder) leaving a cavity in the joint area and the second operation
involves removing flow-induced protrusion via the use of a flat shoulder
(establishment of a common axis is critical for this process). The first
pinless tool with the support of a flat back plate. The removal of key-
step of the MFSC involves the plunging of a rotating cylindrical pin tool
hole/protuberance was reported to improve metallurgical bonding and
with a probe length of 2.4 mm into the work-piece arrangement to es-
joint strength while the presence of alumina nanoparticle further in-
tablish a keyhole and a protuberance on the bottom AA7075-T6 side of
creased the joint strength by 23%. Chen et al. [16] investigated a cir-
the joint (see Fig. 1). In the second step, the protuberance-keyhole
cular-path tool travel approach in eliminating preformed keyhole (in
profile of the joint is plastically leveled (removed) by using a smooth
conventional FSSW process). Joint strength and elongation improve-
backplate (undrilled side) and a larger diameter (probe-less) rotating
ments of about 56% and 81% were obtained in the refilled joint as
tool according to the illustrations of Fig. 1. The tools used for both the
compared to that of conventional FSSW joints (with keyhole). The
first- and second-step operations were fabricated from HSS tool mate-
keyhole refilling process increased the bonding area and conversely
rials while Fig. 1 specified their morphologies and dimensions. Based on
improved the fracture resilience of the refilled joint. Ibrahim and Yapici
the outcome of the preliminary experiment, a constant parameter
[17] investigated a new process of eliminating keyhole which was
combination of 5 s dwell time, 1500 rpm rotational speed and 0.3 mm
termed “intermediate layer friction stir spot welding (IL-FSSW)”. An
plunge depth was employed during the first-step process while only tool
intermediate layer was used to prevent the occurrence of a keyhole in
rotational speed was varied from 630 rpm to 1400 rpm during the
the friction stir spot welded 6061-T6/2024-T3 aluminum alloys. The
second-step of the MFSC process. A constant tool plunge rate of 2 mm/
use of this approach was reported to improve joint appearance and the
min was employed for the joining process. Conventional friction stir
lap shear failure of the joint (for over 4.5 kN). Sun et al. [18] employed
spot welding (FSSW) of the dissimilar AA2024-T3/AA7075-T6 alloys
flat FSSW technique in joining three 6061-T6 Al sheets. The stacked Al
was also carried out with the aid of a cylindrical pin tool (the tool used
sheet was joined in a two-step approach. The first step includes the
for the first-step of MFSC process) in order to compare and assess the
creation of metallurgical bonded protuberance and keyhole on the
effect of friction stir clinching on the joint properties.
bottom-side of the stacked sheets (bowl-like stir zone is formed) while
The cross-sections of the MFSC welds were obtained, ground, po-
the removal of these defects via the use of a probeless rotating tool is
lished and etched according to the standard metallographic procedures
the second operation carried out on the joint. This joining technique
To reveal the microstructure of the joint, Keller’s reagent (1 ml HF,
produced a longer bonding length (11.5 mm) and a higher failure load
1.5 ml HCl, 2.5 ml HNO3, 95 ml H2O) for 15 s and Weck’s reagent
of about 6.4 kN.
(100 ml H2O + 1 g NaOH + 4 g KMnO4) was applied for 10 s on the
A novel approach for removing joint protrusion similar to the works
polished joint surfaces. The samples were viewed under an optical
of Enami et al. [15] is thus adopted and studied in this paper because
microscope (OM) and scanning electron microscope (SEM). Elemental
the approach has a paucity of information in literature on dissimilar
compositions of the metallurgical bonded joint areas were determined
aluminum alloys. Accordingly, a modified friction stir clinching tech-
via the use of energy dispersive X-ray (EDX). Tensile-shear and cross-
nique is employed to join dissimilar 2024-T3 and 7075-T6 Al alloy
tensile tests were performed on the MFSC weld samples according to JIS
sheets with a view of improving the bonded length/width and elim-
Z3136 and JIS Z3137 standards respectively at a displacement of 1 mm/
inating stress-concentration prone keyhole and flow-induced protu-
min. The schematic representations of the test samples are shown in
berance in the joint area. The mechanical properties and micro-
Figs. 2 and 3 respectively. The fracture surfaces of the weld are ex-
structures of the fabricated joints were studied while the fracture
amined in a scanning electron microscope (SEM) in order to clarify the
morphologies of the failed joints were examined.
fracture mode of the joint.

2. Materials and methods

3. Results and discussion

AA2024-T3 (1.6 mm thick) and AA7075-T6 (2 mm thick) Al alloy

3.1. Macrostructure
sheets were used as the base materials for this research. Tables 1 and 2
provide the mechanical properties and the chemical compositions of the
Fig. 4 reveals the surface appearances of the joints obtained via the
Al alloys respectively.
modified friction stir clinching technique (MFSC) and the conventional
Modified friction stir clinching (MFSC) with protuberance-keyhole
FSSW process. Protuberance-keyhole profile has been eliminated in
leveling technique was employed to join the base metals in an over-
Fig. 4a while keyhole and shallow shoulder cavity are present on the
lapped configuration. The AA2024-T3 Al alloy was placed on top of
surface of the conventional FSSW weld (see Fig. 4b) due to the upward
AA7075-T6 Al alloy for the joining process. The MFSC technique is a
extrusion of the plasticized material (out of the stir zone) and the re-
two-step joining process. Prior to the MFSC process, a 4 mm diameter
traction of the cylindrical pin tool (to leave a hollow-space behind/in
pre-drilled hole having a depth of 4 mm is created on the back plate
the stir zone). The flow of material into the pre-drilled hole (on the back
(anvil) required for the welding process. The overlapped work-piece is
plate) forms a protuberance profile at the bottom AA7075-T6 side and a
positioned and rigidly clamped to the back plate in such a way that the
keyhole at the top AA2024-T3 side of the joint (during the first-step of
center of the pre-drilled hole coaxially aligns with that of the tool axis
the MFSC process). The probe-less tool (during the second-step process)
enforces compressive-stirring effect on the flow-induced protuberance
Table 1
and on the surface of the Al alloy (at the bottom AA7075-T6 side of the
Mechanical properties of base alloys (wt.%).
joint). This phenomenon redirects the material protrusion back into the
Alloy Ultimate Tensile [MPa] Yield Strength [MPa] Elongation (%) hollow side/interior of the protrusion and refills it. Further plunging
effect of the probe-less tool into the AA7075-T6 alloy facilitates the
AA2024-T3 448 317 14
AA7075-T6 560 485 12 complete refilling of the protuberance-keyhole cavity in the joint. After
a dwell time of 5 s, the probe-less tool was retracted to leave a smooth

178
M. Paidar, et al.
Fig. 1. Processes involved in the modified friction stir clinching with protuberance-keyhole leveling.
surface appearance at the AA7075-T6 side and a smeared appearance
with shallow circumferential spacing around the bulk plasticized center
at the AA2024-T3 side (see Fig. 4a). The diameter difference (of 4 mm)
between the tool shoulders used for the first step (10 mm) and second-
step (14 mm) of the MFSC process is adjudged to be responsible for the
presence of shallow circumferential spacing around the bulk plasticized
center (at the AA2024-T3 side in Fig. 4a). The resultant surface ap-
pearance of the MFSC joint (after the second-step process) at the
AA7075-T6 side is similar to that of a conventional pinless-assisted
FSSW weld having a smooth appearance and a minimal surface flash.
Fig. 4a shows a smeared appearance at the top surface (of the
AA2024-T3 side) after the second step of the MFSC process. This oc-
currence is due to the contact/rubbing effect between the Al alloy and
the supporting backplate. The shoulder plunge depth (0.3 mm) con-
strains the flow of material back into the hollow side of the protrusion
to a definite depth. This occurrence establishes a somewhat partial
Fig. 2. Schematic illustration of the tensile-shear specimen based on JIS Z3136 standard.
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Journal of Manufacturing Processes 41 (2019) 177–187
contact between the downward-flowing plasticized material and the
back plate/anvil. No metallurgical bonding is formed at the interfacial
region between the hard (un-deformed) backing plate and the down-
ward-flowing plasticized material (during the second step of the MFSC
process). As a result, smeared appearance ensue at the AA2024-T3 side
after the removal of the welded sample. On the other hand, the smear
appearance at the periphery of the stir zone in Fig. 4a, is owing to the
effect of clamping on the interface between the work-piece arrange-
ment and the backplate. The periphery of AA2024-T3 side had under-
gone severe plastic deformation during the first-step of the MFSC pro-
cess and on contact with a hard surface (under rigid clamping and
welding) easily deformed and produced such a smeared appearance in
Fig. 4a.
Fig. 5 shows the cross-sectional views of MFSC and conventional
FSSW joints. The MFSC joints (in Fig. 5) confirm the presence of a
shallow circumferential spacing around the bulk plasticized material at
M. Paidar, et al.
Fig. 3. Schematic illustration of the cross-tensile specimen based on JIS Z3137
standard.
the AA2024-T3 side. The red arrows on Fig. 5 depict the boundaries of
the tool shoulder (10 mm) during the first step of the MFSC process. The
backward flow or refilling of the inherent cavity (protuberance-keyhole
profile) establishes the circumferential spacing (see the red arrows) at
Fig. 4. Surfaces of the joint produced by (a) MFSC process, (b) conventional FSSW process.
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Journal of Manufacturing Processes 41 (2019) 177–187
the AA2024-T3 side during the second-step of the MFSC process due to
the different sizes of the tool shoulders (in the first- and second- steps of
MFSC process). Hook defect is eliminated in the MFSC joints. However,
flow-induced defects are present on the AA2024-T3 side while such
defect is absence on the AA7075-T6 side of the MFSC joints. The larger
diameter of the probe-less tool is responsible for the absence of a defect
on the AA7075-T6 side as the through-thickness material flow is en-
forced on the bottom (AA7075-T6) side. However, the presence of a
step-like cavity (shoulder-keyhole/protuberance interior cavity) on the
AA2024-T3 side (after the first-step MFSC process) creates a refilling
challenge which is greatly influenced by the process parameter com-
bination. The highest tool rotational speed (1400 rpm) eliminates the
weld center flow-induced defect while the circumferential width defect
(shoulder induced defect) is narrowed as the tool rotational speed is
increased (at the AA2024-T3 side).
In another perspective, the red arrow regions are the edges of the
shallow shoulder cavities (produced in the first-step MFSC process)
where geometrical changes occur during the refilling process (second-
step MFSC process). The upper side (center) of the AA2024-T3 alloy has
notable center defects at reduced tool rotational speeds (630 rpm and
1000 rpm). During the refilling process, geometrical changes owing to
the keyhole (at the weld center) could be responsible for the weld
center defect observed in Fig. 5. The severity of the center defect is
pronounced at a lower speed (630 rpm) while it is absent in the joint
produced at 1400 rpm. This occurrence indicates that better material
flow (reduced viscosity) is established at higher tool rotational speed in
M. Paidar, et al. Journal of Manufacturing Processes 41 (2019) 177–187

Fig. 5. Microstructures of the modified friction stir clinched joint and friction stir spot welded joints.

Fig. 6. Microstructure of the MFSC joints obtained at (a) 630 rpm, (b) 1000 rpm, (c) 1400 rpm.

the MFSC joint in order to eliminate weld center defect. It can be
concluded that an increase in the tool rotational speed reduces the flow-
induced weld center defect (at the top sheet) while the circumferential
(width) spacing is narrowed at the same time (at the top sheet). Also, an
increase in tool rotational speed enforces the transport/flow of the
bottom alloy (7075-T6) into the upper alloy (2024-T3) in the MFSC
joints.
On the other hand, the cross-sections of the FSSW joint (see Fig. 5)
have a typical morphology with an inherent keyhole defect. The width
of the section marked as the stir zone (SZ) in Fig. 5 increases with an
increase in the tool rotational speed (from 630 rpm to 1400 rpm) when
the plunge depth (0.3 mm) is kept constant. This phenomenon is at-
tributed to the amount of heat input induced during the FSSW process
because a high heat input is synonymous to a high level of tool rota-
tional speed around the tool-material interface. As a result, an increase
in heat input (rotational speed) increases the width of the heated zone,
improves flowability and consequently increases the width of the stir
zone (SZ) around the probe profile. Likewise, the width of the whitish
SZ decreases down the circumferential height of the SZ. This occurrence
is owing to the dominant amount of heat that is generated at the
shoulder-material interface region. This agrees with the findings of Chu
et al. [19] as peak temperature and plastic-strain was reported to occur
at the inner shoulder edge (owing to higher heat flux around the
shoulder).

181
M. Paidar, et al.
Fig. 7. Micrographs of clinched and stirred regions of the MFSC joints.
Fig. 8. Average grain sizes in the stir zone of the MFSC joints.
3.1.1. Microstructure
Fig. 6 shows the microstructure of the MFSC joints obtained at
different tool rotational speeds. The friction stir clinching effect of the
joining process facilitates large inter-material mixed width at the clin-
ched and stirred regions as indicated by the red arrows on Fig. 6. The
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Journal of Manufacturing Processes 41 (2019) 177–187
arrows show a large width within the center of the stir region where
intermixing has taken place. The degree of intermixing is enhanced as
the level of tool rotational speed is increased as evidence of improperly
mixed material flow-path is observed at a lower speed of 630 rpm while
insignificantly mixed flow-path is absence in the clinched and stirred
region at higher tool rotational speed. This occurrence is attributed to
the level of induced frictional heat input on viscosity and material
transport. More material flowability ensues at higher tool rotational
speed and this enforces better material intermixing or elimination of
improperly mixed inter-material flow-path [20,21]. Zhou et al. [22]
reported that higher peak temperature and material softening ensue as
the tool rotational speed is increased while the torque and plunging
force become lowered. This phenomenon facilitates material transport
and mixing at the stir zone.
Fig. 7 shows the stirred sides of the MFSC joints. The dark patches
on the micrograph are attributed to the etching effect. Grain refinement
occurs at both the upper (AA2024-T3) and lower (AA7075-T6) sides of
the MFSC joints owing to the drastic plastic deformation as revealed in
Fig. 7. The Appendix reveals the microstructures of the critical weld
zone. The microstructure of the joints (both MFSC and FSSW) follows
the normal convention by having a stir zone (SZ), and thermo-me-
chanical affected zone (TMAZ) around the weld nugget [23–27].
Equiaxed fine grains are present at the SZ while coarseness of the grains
M. Paidar, et al.
Fig. 9. EDS results and mapped images of the clinched and stirred region of MFSC joint.
increases towards the HAZ. This observation agrees with the works of
Ojo et al. [28] and Paidar et al. [29]. The evolution of such micro-
structure in the friction stir welded aluminum joints has been attributed
to continuous dynamic recrystallization (CDRX), geometric dynamic
recrystallization (GDRX) and particles stimulated nucleation (PNS)
(owing to the high stacking fault energy of Al alloys) [18,30]. Grain
refinement in the alloy has also been attributed to higher peak tem-
perature and larger strain and strain rates in the stir zone during the
welding process [31].
The severe plastic deformation produced equiaxed grains at the
AA2024-T3 side while a combination of elongated and equiaxed grains
is formed at the AA7075-T6 side (when a probe-less tool was used) as
revealed in Fig. 7. Such elongated grains in the AA7075-T6 alloy is
described as spindly rolled grains in the works of Song et al. [32]. Sa-
farbali et al. [33] stated that the band structures obvious on the
AA7075-T6 side are owing to the high cooling rate experienced at the
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Journal of Manufacturing Processes 41 (2019) 177–187
welded joint. Heat input from the probe-less tool facilitates significant
driving force for elemental diffusion and the band structures are less
discernible. The fast cooling rate of the joint ensures that the structures
do not completely disappear after welding. Similarly, Srinivas and
Devaraju [34] reported that distinctive lamellar bands (band structures)
observed in the SZ of AA7075-T6 alloy are attributed to the degrees of
intermixing between the respective base metals. Zhang et al. [31] re-
ported that AA7075 Al alloy has a higher thermal conductivity when
compared with that of AA2024 alloy. The AA7075 alloy is more sen-
sitive to induced thermal energy (heat input) during FSSW and thus
heat diffusion per unit time is higher in the bottom (AA7075) alloy. The
presence of band structures at the AA7075-T6 side could be due to the
disparity in the thermal conductivity of the base metals (as more heat
input is expected to be generated at the probe-less side). Likewise, this
phenomenon could be responsible for the intense diffusion of the
AA7075-T6 alloy into the AA2024-T3 alloy observed in the macrograph
M. Paidar, et al.
Fig. 10. Failure load of welded joints.
shown in Fig. 7.
The average grain sizes of the AA2024-T3 and AA7075-T6 Al sheets
(base metals) are 15 and 21 μm respectively. Fig. 8 reveals the average
grain sizes of the MFSC joints’ stir zone as a function of the tool rota-
tional speed. The increase in the tool rotational speed (from 630 rpm to
1400 rpm) causes an increase in the average grain sizes of the stir zone
from approximately 4 μm–8 μm (see Fig. 8). An increase in tool rota-
tional speed induces more frictional heat input in the stir region of the
MFSC joints. The thermal heat generational phenomenon in the weld is
adjudged to aid grain coarsening and cause the observed increase in the
average grain sizes shown in Fig. 8 as the tool rotational speed is in-
creased. However, grain boundary pinning technique (via the use of
reinforcements) is an effective approach of preventing grain growth in
Al alloys when there is more induced heat input during friction stir
(spot) welding process [35].
Fig. 9 reveals the EDS results of the MFSC joints (clinched and
stirred region) while the mapped sections confirm the presence of major
alloying elements. The EDS assessment of the notable points on the
micrograph of the stir zone (see Fig. 9) was carried out. Point “A” has
68.67 wt% Al, 18.75 wt% Cu and 12.57 wt% Mg respectively while
point “B” has 46.68 wt% Al, 25.52 wt% Cu, 12.85 wt% Mg, and
14.95 wt% Zn respectively. The induced frictional stirring action of the
welding tool facilitates inter-material mixing and diffusion to form
phases within the weld nugget. The assessment of the notable features
on the micrographs reveals the presence of Al2CuMg and Mg2Si phases
at the SZ while Al2CuMg and MgZn2 phases are present in the TMAZ
and HAZ respectively.
3.1.2. Tensile properties and fractography
Fig. 10 shows that the MFSC joints produced superior failure loads
under the tension-shearing condition as the level of tool rotational
speed is increased. The failure load of the MFSC joints subjected to
tensile-shear loading increased from 6798 N to 9487 N as the tool ro-
tational speed was increased from 630 rpm to 1400 rpm while that of
the cross-tension loaded samples also increased from 4366 N to 6850 N.
This occurrence has been attributed to the effect of increased thermal
input and better material flow by Li et al. [13] in the joint area. Better
material intermixing and bonding ensue at higher tool rotational speed
in the MFSC joint. Likewise, the severity of the flow-induced weld de-
fect in the MFSC joint decreases with the increase in the level of tool
rotational speed. This attribute could be responsible for the direct re-
lationship between the failure load and the tool rotational speed re-
vealed in Fig. 10. A comparison of the best MFSC joint (having the
highest failure load) with that of the conventional FSSW joint is shown
in Fig. 10 (at 1400 rpm). The MFSC processing effect increased the
tensile-shearing and cross-tensile resistances of the AA2024-T3/
AA7075-T6 joints by failure load differences of 2689 N and 2600 N
184
Journal of Manufacturing Processes 41 (2019) 177–187
respectively. The improvement in the failure load of the joint is at-
tributed to the bonding mechanism employed in joining the dissimilar
base metals (AA2024-T3/AA7075-T6). The refilled protuberance-key-
hole profile in the second-step of the MFSC process is adjudged to have
increased the effective bonded (shear) area and the area on which stress
acts under axial loading. This occurrence will restrain crack initiation,
fracture resilience and failure load in the MFSC joint. The larger bonded
area (without keyhole) improves the load-bearing ability of the MFSC
joints as compared to that of the FSSW joint (with an inherent keyhole
that limits the joint’s effective shear area). Safarbali et al. [33] revealed
that fine grains and the presence of uniformly dispersed MgZn2 pre-
cipitates enhanced the tensile properties of friction stir welded joint of
2024-T4/7075-T6 Al alloys. Niu et al. [36] revealed that the strength-
ening precipitates of AA2024 Al alloys are owing to the dominant
Guinier-Preston-Bagaryatsky (GPB) zones in the alloy. The induced heat
input is adjudged to dissolve the GPBs in the alloy during welding and
the natural aging process facilitates their precipitation.
Shear failure through the stir zone is observed in Fig. 11. The arrows
in Fig. 11 (on the fracture macrograph) indicate the fracture path in the
MFSC joints. The failure occurs through the weld center and through
the shoulder edge (at the top AA2024-T3 side) as revealed in Fig. 11.
According to Li et al. [13], stir zone shape and hook defects (with acute
hook angles) are the inherent factors that control the shear strength of
probe-less joint. However, the MFSC joint is devoid of hook profile/
defect but it has geometric-differential flow-induced defects at the weld
center (owing to protrusion refilling) and at circumferential shoulder
edge (owing to the refilling of the shoulder indentation) (see Section 3.1
or Figs. 4 and 5). Fig. 11 reveals that the final joint failure ensues
through these notable defected zones in the clinched and stirred zone of
the joint. On the other hand, the MFSC welded zone undergoes a de-
flection under axial loading. Ojo et al. [37] stated that such a defection
enforces re-orientation of the weld nugget under loading in order to
guarantee that the line of force aligns with the center of gravity (cen-
troid) of the welded joint. As a result, the plasticization of the inter-
facial bonded edge between the upper and the lower sheet ensues.
Continuous loading of the joint initiates crack at the plasticized inter-
facial (bonded) edge and propagates into the stir zone (defected region)
of the joint to give the macrograph revealed in Fig. 11. Li et al. [13] also
stated that the sample orientation phenomenon ensures that the normal
force is larger along the top sheet and causes top sheet crack propa-
gation under continuous axial loading. Thus, this phenomenon is ad-
judged to be responsible for the top sheet final failure (through the
flow-induced defects) observed in the MFSC joints. The MFSC process
eliminates circumferential failure path which is typical with the con-
ventional FSSW (with keyhole) joints owing to the refilled protuber-
ance-keyhole of the joint.
On the other hand, the assessment of the fracture surfaces (in
Fig. 11) reveals the presence of shallow dimples which confirm the
occurrence of ductile fracture mode in the MFSC joints. This fracture
mode is attributed to the refined grain structures in the clinched and
stirred zone of the MFSC joint. The improved MFSC joint strength
(failure load) may be owing to the failure through the stir zone. The stir
zone has fine grains which correspond to an increase in the volume of
grain boundary (much multiple grain boundaries). Paidar et al. [38]
reported that fine grain sizes enforce less dislocation pile up (and
driving force) at grain boundaries during axial loading condition. In
view of this, an increased amount of applied load/stress will be re-
quired to push dislocation from grain to grain in the stir zone having
recrystallized fine grains (with multiple grain boundaries). Thus, the
existence of fracture through the clinched and stirred region of the
MFSC joint could be responsible for the observed improvement in the
failure load of MFSC joints.
4. Conclusion
Modified friction stir clinching (MFSC) with protuberance-keyhole
M. Paidar, et al.
Fig. 11. MFSC fracture mode and fracture surfaces.
leveling has been successfully carried out on dissimilar base metals of
AA2024-T3 and AA7075-T6 Al alloys. The mechanical properties, mi-
crostructure and fracture mode of the joint were studied. The findings
of this study are summarized as follow:
i MFSC process eliminates the formation of hook defect in the
AA2024-T3/AA7075-T6 joints but induces two other forms of geo-
metric-differential flow-induced defects at the weld center (owing to
protuberance refilling) and at the circumferential shoulder edge
(owing to the refilling of the shoulder indentation).
ii A rise in tool rotational speed reduces the severity of the flow-in-
duced defects in the MFSC joint due to better flowability and inter-
material mixing.
185
Journal of Manufacturing Processes 41 (2019) 177–187
iii The average grain sizes of the MFSC joint increase from approxi-
mately 4 μm–8 μm as the rotational speed is increased from 630 rpm
to 1400 rpm due to induced heat input.
iv Intermetallic phases of Al2CuMg and Mg2Si are formed in the stir
zone of the MFSC joint owing to atomic diffusion.
v Increase in the tool rotational speed (630–1400 rpm) increases the
tensile-shear and cross-tension loads of the MFSC joints from 6798 N
to 9487 N and 4366 N to 6850 N respectively. This is owing to the
refilled protuberance-keyhole profile and eventual increased effec-
tive bonded (shear) area of the joint.
vi The MFSC joints fail via ductile shear failure mode through the clin-
ched and stirred region of the upper AA2024-T3 side. The flow-in-
duced defects significantly affect the failure mode of the MFSC joint.
M. Paidar, et al.
Appendix A
Fig. 12
Fig. 12. Critical zones of the joint (a) SZ, (b) TMAZ and (c) HAZ.
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