The present work investigates the effect of rotational speed on joint quality during Friction Stir Spot Welding (FSSW) using a consumable pin, where a consumable pin is used with a rigid tool shoulder for welding AA6061-T6 sheets to produce an exit-hole-free FSSW joint. Joint quality was analysed using lap shear test, macrostructure, microstructure and microhardness analysis at five rotational speeds, viz. 360, 462, 557, 900 and 1200 revolutions per minute (RPM). The joint strength increased with increase in rotational speed from 360 RPM to 900 RPM and then decreased with further increase in rotational speed. A 1.7 times increase in joint strength was observed for FSSW at 900 RPM with reference to 360 RPM. As expected, both energy input and temperature increased with rotational speed. The energy input increased by only 27.5% as the rotational speed was increased from 360 to 900 RPM. Finite element (FE) simulations were conducted for validation and study using commercial FE software, DEFORM-3D, to predict temperature distribution, force, torque and material flow. Lap shear test simulations matched with experimental results within reasonable (∼7%) accuracy except for very low rotation cases. However, failure load provided better matching with experimental results when Cockcroft-Latham damage model was used instead of Freudenthal damage model.

目前的工作研究了使用自耗销进行摩擦搅拌点焊 (FSSW) 时转速对接头质量的影响，其中自耗销与刚性工具肩一起使用，用于焊接 AA6061-T6 板材，以产生无出口孔FSSW 接头。使用搭接剪切试验、宏观结构、微观结构和显微硬度分析在五种转速下对接头质量进行分析，即 360、462、557、900 和 1200 转/分钟 (RPM)。接头强度随着转速从360 RPM增加到900 RPM而增加，然后随着转速进一步增加而降低。与 360 RPM 相比，900 RPM 下的 FSSW 接头强度增加了 1.7 倍。正如预期的那样，能量输入和温度都随着转速的增加而增加。能量输入只增加了27。当转速从 360 RPM 增加到 900 RPM 时，增加了 5%。使用商业 FE 软件 DEFORM-3D 进行有限元 (FE) 模拟进行验证和研究，以预测温度分布、力、扭矩和材料流动。除了非常低的旋转情况外，搭接剪切测试模拟与实验结果的匹配精度合理（∼7%）。然而，当使用 Cockcroft-Latham 损伤模型而不是 Freudenthal 损伤模型时，失效载荷与实验结果具有更好的匹配性。除了非常低的旋转情况外，搭接剪切测试模拟与实验结果的匹配精度合理（∼7%）。然而，当使用 Cockcroft-Latham 损伤模型而不是 Freudenthal 损伤模型时，失效载荷与实验结果具有更好的匹配性。除了非常低的旋转情况外，搭接剪切测试模拟与实验结果的匹配精度合理（∼7%）。然而，当使用 Cockcroft-Latham 损伤模型而不是 Freudenthal 损伤模型时，失效载荷与实验结果具有更好的匹配性。