Modelling and visualisation of material flow in friction stir spot welding

Aidan Reilly, Hugh Shercliff*, Yingchun Chen, Philip Prangnell

*Corresponding author for this work

    Research output: Contribution to journalArticlepeer-review

    30 Citations (Scopus)


    Abstract The material flow in friction stir spot welding of aluminium to both aluminium and steel has been investigated, using pinless tools in a lap joint geometry. The flow behaviour was revealed experimentally using dissimilar Al alloys of similar strength. The effect on the material flow of tool surface features, welding conditions (rotation speed, plunge depth, dwell time), and the surface state of the steel sheet (un-coated or galvanized) have been systematically studied. A novel kinematic flow model is presented, which successfully predicts the observed layering of the dissimilar Al alloys under a range of conditions. The model and the experimental observations provide a consistent interpretation of the stick-slip conditions at the tool-workpiece interface, addressing an elusive and long-standing issue in the modelling of heat generation in friction stir processing.

    Original languageEnglish
    Pages (from-to)473-484
    Number of pages12
    JournalJournal of Materials Processing Technology
    Early online date23 Jun 2015
    Publication statusPublished - Nov 2015


    • Aluminium alloys
    • Automotive alloys
    • Dissimilar materials
    • Friction stir spot welding
    • Galvanised steel
    • Process modelling

    ASJC Scopus subject areas

    • Computer Science Applications
    • Modelling and Simulation
    • Ceramics and Composites
    • Metals and Alloys
    • Industrial and Manufacturing Engineering

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