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1770385 
Journal Article 
Preliminary Study on the Mechanical Behavior of Friction Spot Welds 
Esmerio Mazzaferro, JA; Rosendo, TdeS; Petry Mazzaferro, CC; Ramos, FD; Durlo Tier, MA; Strohaecker, TR; dos Santos, JF 
2009 
1 
Revista Soldagem & Inspeção
ISSN: 0104-9224
EISSN: 1980-6973 
14 
3 
238-247 
WOS:000271179500007 
The Friction Spot Welding - FSpW is a solid-state process
that allows joining two or more metal sheets in lap configuration with no residual keyhole as
occurs in the Friction Stir Welding - FSW process. The present work reports part of the efforts
made at GKSS Research Centre to better understand the complex phenomena that take place during
FSpW of aluminum alloys and establish the mechanical response of the resulting joints. Over the
recent years the research on modeling friction based welding processes has increased
considerably. Most of the works related to this subject deal with the process mechanics. On the
other hand, some investigations have shown how the process variables affect the mechanical
properties of the joints, but it is very difficult to find quantitative results that can be
readily used for mechanical design purposes. The aim of this work is to develop an analysis
procedure based on the process characteristics that allows evaluating how the resulting geometry
and microstructure affect the joint mechanical behavior For this, the results of the mechanical
tests obtained on AA2024-T3 aluminum alloy were used to calibrate and validate a numerical model
that was used to predict the joint failure mode. The model reproduced the specimen geometry and
load conditions adopted in the lap-shear and cross-tensile tests. The joint was considered as
formed by three main regions (SZ - stir zone, TMAZ - thermo mechanically affected zone and HAZ -
heat affected zone) whose properties and dimensions were based in microhardness evaluation and
macrographic analysis of welded specimens. It was observed a good agreement between the
simulation results and experimental data. The numerical modeling of the joints allows the
prediction of the joint mechanical properties, as well as to understand how a change in geometry
and property of each region affects the final mechanical behavior Based in the obtained results,
the analysis procedure can be easily extended to the related friction based spot processes as
Friction Stir Spot Welding - FSSW. 
Friction Spot Welding; FSpW; failure mode