Evaluating the Influence of Tool Material on the Performance of Refill Friction Stir Spot Welds in AA2029

Joining high strength 2xxx series aluminum is known to be complex and difficult; these alloys are traditionally considered non-weldable for fusion welding. This paper describes details on welding AA2029-T8 for skin-stiffened structures using refill friction stir spot welding (RFSSW). RFSSW is a solid-state process invented in the early 2000s that produces spot welds that are strong, lightweight, flush, and hermetic. Cycle times between 1 and 3 s are discussed, and process forces within a range of 8 to 14 kN are demonstrated. Furthermore, lap-shear quasi-static tensile strengths are shown to be between 10 kN and 12 kN in 9 mm diameter spots. A comparison of the performance of RFSSW welds made with various tool materials—which include H13 tool steel, tungsten carbide, and MP159—is detailed. Comparisons of parameters, weld consolidation, and heat-affected zones are presented with discussion related to heat generation specific to each tool material.