Preliminary Study of FSW Process of Dissimilar Aluminium Alloys in Battery Pack Assembly for Hybrid Vehicles Production

Abstract

The requirement to join two dissimilar aluminium alloys produced with two different technological processes, extrusion and die casting, is fundamental in the automotive sector. In this research study was proposed the use of the Friction Stir Welding process to replace the traditional welding process. First of all was verified the weldability by using different process parameters and the results are reported in terms of microstructure and join aspect, which influence the Vickers microhardness. They show a suitable combination between the selected process parameters and the tool choice but also suggest to test different process conditions. Tool geometry and workpiece setup have to be redesigned. The final aim of this preliminary study is to find the best process conditions in order to proceed with components and machine tools design in the perspective of procedure industrialisation for hybrid vehicles battery pack assembly.