Transient Local Melting in Al 7075-T6 Friction Stir Spot Welds

Abstract

Transient local melting can account for the remarkable decrease in the strain rate when the tool rotational speed, heating rate and cycle time produce temperatures exceeding the 475 °C in Al 7075-T6 spot welds. The calculated strain rate is about 20 s-1 in Al 7075-T6 spot welds produced using tool rotational speeds from 1500 RPM to 3000 RPM and dwell time of 4 s. However, the peak temperature is less than less than 475 °C when a low tool rotational speed setting (1000 RPM) is used; transient local melting and tool slippage are precluded and the calculated strain rate is high (about 650 s-1). It is proposed that transient local melted films directly influence formation of the stir zone microstructure in Al 7075- T6 spot welds. It is suggested that the stir zone microstructure in spot welds made using high tool rotational speed settings are determined by a combination of grain boundary sliding and the limitation of cavity interlinkages when transient local melted films form.